U.S. patent application number 15/644458 was filed with the patent office on 2018-02-01 for systems and methods for automated diagnostics of hvac systems.
The applicant listed for this patent is Johnson Controls Technology Company. Invention is credited to Shaun B. Atchison, Jedidiah O. Bentz, Theresa Thy N. Gillette, Shawn A. Hern, Tyler P. McCune, Aneek M. Noor, Brian D. Rigg, Tom R. Tasker, John W. Uerkvitz.
Application Number | 20180032969 15/644458 |
Document ID | / |
Family ID | 61009841 |
Filed Date | 2018-02-01 |
United States Patent
Application |
20180032969 |
Kind Code |
A1 |
Gillette; Theresa Thy N. ;
et al. |
February 1, 2018 |
SYSTEMS AND METHODS FOR AUTOMATED DIAGNOSTICS OF HVAC SYSTEMS
Abstract
A heating, ventilation, and air conditioning (HVAC) system
includes a controller associated with a residence. The controller
is configured to determine an expected value range for an operating
parameter of a component of the HVAC system. Additionally, the
controller is configured to receive a signal from a sensor
indicative of a current value of the operating parameter of the
component and determine if the current value of the operating
parameter is outside the expected value range. Based on the
determination that the current value is outside the expected value
range, the controller is additionally configured to initiate a
diagnostic mode of the controller. In the diagnostic mode, the
controller is configured to collect diagnostic data associated with
the HVAC system.
Inventors: |
Gillette; Theresa Thy N.;
(Wichita, KS) ; Bentz; Jedidiah O.; (Wichita,
KS) ; Rigg; Brian D.; (Douglass, KS) ; Hern;
Shawn A.; (Derby, KS) ; Tasker; Tom R.;
(Andover, KS) ; Atchison; Shaun B.; (Wichita,
KS) ; McCune; Tyler P.; (El Dorado, KS) ;
Noor; Aneek M.; (Wichita, KS) ; Uerkvitz; John
W.; (Valley Center, KS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson Controls Technology Company |
Glendale |
WI |
US |
|
|
Family ID: |
61009841 |
Appl. No.: |
15/644458 |
Filed: |
July 7, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62367307 |
Jul 27, 2016 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 11/52 20180101;
G05B 2219/2614 20130101; H04L 67/10 20130101; G06Q 10/1095
20130101; F24F 11/89 20180101; F24D 19/10 20130101; G06Q 10/20
20130101; F24F 2110/30 20180101; F24F 11/38 20180101; F24F 2140/60
20180101; F24F 1/0003 20130101; F24F 11/61 20180101; G05B 19/042
20130101; F24F 2110/10 20180101; F24F 2110/40 20180101; G05B 19/048
20130101; F24F 11/58 20180101 |
International
Class: |
G06Q 10/10 20060101
G06Q010/10; G05B 19/048 20060101 G05B019/048; H04L 29/08 20060101
H04L029/08; G06Q 10/00 20060101 G06Q010/00; F24D 19/10 20060101
F24D019/10; F24F 11/02 20060101 F24F011/02 |
Claims
1. A heating, ventilation, and air conditioning (HVAC) system,
comprising: a controller associated with a residence, wherein the
controller is configured to: determine an expected value range for
an operating parameter of a component of the HVAC system; receive a
signal from a sensor indicative of a current value of the operating
parameter of the component; determine if the current value of the
operating parameter is outside the expected value range; based on
the determination that the current value is outside the expected
value range, initiate a diagnostic mode of the controller, wherein
in the diagnostic mode, the controller is configured to collect
diagnostic data associated with the HVAC system.
2. The HVAC system of claim 1, wherein the controller is configured
to transmit the diagnostic data to a service center for analysis to
identify proposed maintenance actions for the component.
3. The HVAC system of claim 1, wherein the controller is configured
to transmit the diagnostic data to a cloud database for access by a
service center.
4. The HVAC system of claim 1, wherein the expected value range is
determined based on baseline data collected from a baseline test,
wherein the baseline test includes monitoring operation of a test
component similar to the component.
5. The HVAC system of claim 1, wherein the component comprises a
residential indoor unit, a residential outdoor unit, a residential
heat exchanger, a residential fan, a residential blower, a
residential furnace system, a residential blower, a residential
refrigerant conduit, a residential section of ductwork, or a
combination thereof.
6. The HVAC system of claim 1, wherein the operating parameter
comprises an operating pressure, an operating temperature, an
operating leaving air temperature, operating EEV data, operating
air flow rate, operating outdoor fan data, operating power usage
data, or a combination thereof
7. The HVAC system of claim 1, wherein the operating parameter
comprises a status indicator of the component, wherein the status
indicator comprises an indication that the component comprises a
healthy status or a fault status, wherein the healthy status is
indicated by the current value within the expected value range, and
wherein the fault status is indicated by the current value outside
of the expected value range.
8. The HVAC system of claim 1, wherein the diagnostic data is
collected at a greater frequency, for a greater length of time, or
a combination thereof compared to the receipt of the signal.
9. The HVAC system of claim 1, wherein the controller is configured
to: determine an additional expected value range for an additional
operating parameter of an additional component of the HVAC system:
receive an additional signal from an additional sensor indicative
of an additional current value of the additional operating
parameter of the additional component; determine if the additional
current value of the additional operating parameter is outside the
additional expected value range; based on the determination that
the current value of the operating parameter of the component is
outside the expected value range and the determination that the
additional current value of the additional operating parameter of
the additional component is outside the additional expected value
range, initiate an extreme diagnostic mode, wherein in the extreme
diagnostic mode, the controller is configured to collect the
diagnostic data at a greater frequency, for a greater length of
time, or a combination thereof compared to collection of the
diagnostic data during the diagnostic mode.
10. The HVAC system of claim 1, wherein the controller is
configured to: determine if the diagnostic mode has not been
initiated during a certain time period; and based on the
determination that the diagnostic mode has not been initiated
during the certain time period, initiate the diagnostic mode of the
controller.
11. The HVAC system of claim 10, wherein the certain time period is
a period of time before a high-use season of the HVAC system.
12. The HVAC system of claim 1, wherein the controller is
configured to: determine if the diagnostic mode has not been
initiated within an elapsed time threshold; and based on the
determination that the diagnostic mode has not been initiated with
the elapsed time threshold, initiate the diagnostic mode of the
controller.
13. The HVAC system of claim 1, comprising a user interface
communicatively coupled to the controller, and wherein the
controller is configured to: determine if user input indicative of
a request to initiate the diagnostic mode has been received; and
based on the determination that the user input indicative of the
request to initiate the diagnostic mode has been received, initiate
the diagnostic mode of the controller.
14. The HVAC system of claim 1, comprising a user interface
communicatively coupled to the controller, wherein the controller
is configured to receive additional signals from the user interface
indicative of user settings for the controller, and wherein the
controller is configured to operate the HVAC system based at least
in part on the user settings.
15. A method for performing a diagnostic mode for a controller
associated with a residential heating, ventilation, and air
conditioning (HVAC) system, comprising: determining an expected
value range for an operating parameter of a component of the HVAC
system; receiving a signal from a sensor indicative of a current
value of the operating parameter of the component; determining if
the current value of the operating parameter is outside the
expected value range; based on the determination that the current
value is outside the expected value range, initiating a diagnostic
mode of the controller; and in the diagnostic mode, collecting
diagnostic data associated with the HVAC system.
16. The method of claim 15, comprising: transmitting the diagnostic
data to a service center for determination of a proposed
maintenance action; and receiving the proposed maintenance action
or a request to schedule the proposed maintenance action from the
service center.
17. The method of claim 15, comprising collecting the diagnostic
data at a greater frequency, for a greater length of time, or a
combination thereof compared to collecting operating parameter data
while not in the diagnostic mode.
18. The method of claim 15, comprising: determining if the
diagnostic mode has not been initiated during a certain time
period; and based on the determination that the diagnostic mode has
not been initiated during the certain time period, initiating the
diagnostic mode of the controller.
19. The method of claim 15, comprising: determining if the
diagnostic mode has not been initiated within an elapsed time
threshold; and based on the determination that the diagnostic mode
has not been initiated with the elapsed time threshold, initiating
the diagnostic mode of the controller
20. One or more non-transitory computer-readable storage medium
storing processor-executable instructions, wherein the
instructions, when executed by a processor of a controller, cause
the processor to: determine an expected value range for an
operating parameter of a component of a residential heating,
ventilation, and air conditioning (HVAC) system; receive a signal
from a sensor indicative of a current value of the operating
parameter of the component; determine if the current value of the
operating parameter is outside the expected value range; based on
the determination that the current value is outside the expected
value range, initiate a diagnostic mode of the controller; and in
the diagnostic mode, collect diagnostic data associated with the
HVAC system.
21. The non-transitory computer-readable storage medium of claim
20, wherein the instructions, when executed by the processor of the
controller, cause the processor to: transmit the diagnostic data to
a service center for determination of a proposed maintenance
action.
22. The non-transitory computer-readable storage medium of claim
21, wherein the instructions, when executed by the processor of the
controller, cause the processor to: receive the proposed
maintenance action or a request to schedule the proposed
maintenance action from the service center.
23. The non-transitory computer-readable storage medium of claim
20, wherein the expected value range is determined from baseline
data transmitted from a service center.
24. The non-transitory computer-readable storage medium of claim
20, wherein the expected value range is determined by accessing a
cloud database comprising the expected value range, wherein the
expected value range is previously determined from baseline data
determined during baseline tests.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from and the benefit of
U.S. Provisional Patent Application No. 62/367,307, entitled
"AUTOMATED DIAGNOSTICS," filed Jul. 27, 2016, which is hereby
incorporated by reference.
BACKGROUND
[0002] The present disclosure relates generally to heating,
ventilating, and air conditioning systems (HVAC), and more
particularly to systems and methods for automated diagnostics of
the HVAC systems.
[0003] A wide range of applications exist for HVAC systems. For
example, residential, light commercial, commercial, and industrial
systems are used to control temperatures and air quality in
residences and buildings. Generally, HVAC systems may circulate a
fluid, such as a refrigerant, through a closed loop between an
evaporator where the fluid absorbs heat and a condenser where the
fluid releases heat. The fluid flowing within the closed loop is
generally formulated to undergo phase changes within the normal
operating temperatures and pressures of the system so that
quantities of heat can be exchanged by virtue of the latent heat of
vaporization of the fluid.
[0004] As such, HVAC systems employ many components to provide
heated, cooled, and/or dehumidified air to conditioned
environments. To maintain proper operation of the components, HVAC
systems may be inspected and repaired, especially during winter and
summer seasons when the HVAC systems may be used more heavily.
However, during normal operation, the HVAC systems may experience
one or more issues that go unnoticed, thus, negatively affecting
performance. Additionally, the reduced performance may eventually
lead to increased repair or replacement of certain components of
the HVAC systems. Accordingly, it may be desirable to provide
diagnostic information about operation of the HVAC system more
regularly and more reliably to increase efficiency of the HVAC
system, as well as to identify issues before the issues
progress.
SUMMARY
[0005] In one embodiment of the present disclosure, a heating,
ventilation, and air conditioning (HVAC) system includes a
controller associated with a residence. The controller is
configured to determine an expected value range for an operating
parameter of a component of the HVAC system. Additionally, the
controller is configured to receive a signal from a sensor
indicative of a current value of the operating parameter of the
component and determine if the current value of the operating
parameter is outside the expected value range. Moreover, based on
the determination that the current value is outside the expected
value range, the controller is configured to initiate a diagnostic
mode of the controller. In the diagnostic mode, the controller is
configured to collect diagnostic data associated with the HVAC
system.
[0006] In another embodiment of the present disclosure, a method
for performing a diagnostic mode for a controller associated with a
residential heating, ventilation, and air conditioning (HVAC)
system includes determining an expected value range for an
operating parameter of a component of the HVAC system. The method
also includes receiving a signal from a sensor indicative of a
current value of the operating parameter of the component and
determining if the current value of the operating parameter is
outside the expected value range. Additionally, based on the
determination that the current value is outside the expected value
range, the method includes initiating a diagnostic mode of the
controller. In the diagnostic mode, the method further includes
collecting diagnostic data associated with the HVAC system.
[0007] In a further embodiment of the present disclosure, one or
more non-transitory computer-readable storage medium storing
processor-executable instructions, such that the instructions, when
executed by a processor of a controller, cause the processor to
determine an expected value range for an operating parameter of a
component of a residential heating, ventilation, and air
conditioning (HVAC) system. The instructions also cause the
processor to receive a signal from a sensor indicative of a current
value of the operating parameter of the component and determine if
the current value of the operating parameter is outside the
expected value range. Based on the determination that the current
value is outside the expected value range, the instructions also
cause the processor to initiate a diagnostic mode of the
controller. In the diagnostic mode, the instructions further cause
the processor to collect diagnostic data associated with the HVAC
system.
[0008] Other features and advantages of the present application
will be apparent from the following, more detailed description of
the embodiments, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
application.
DRAWINGS
[0009] FIG. 1 is an illustration of an embodiment of a commercial
or industrial HVAC system, in accordance with the present
techniques;
[0010] FIG. 2 is an illustration of an embodiment of a packaged
unit of the HVAC system shown in FIG. 1, in accordance with the
present techniques;
[0011] FIG. 3 is an illustration of an embodiment of a split system
of the HVAC system shown in FIG. 1, in accordance with the present
techniques;
[0012] FIG. 4 is a schematic diagram of an embodiment of a
refrigeration system of the HVAC system shown in FIG. 1, in
accordance with the present techniques;
[0013] FIG. 5 is a schematic diagram of an embodiment of the HVAC
system shown in FIG. 1 having a control system, in accordance with
the present techniques; and
[0014] FIG. 6 is a flowchart of a method for performing diagnostics
with the control system shown in FIG. 5, in accordance with the
present techniques.
DETAILED DESCRIPTION
[0015] The present disclosure is directed to heating, ventilation,
and air conditioning (HVAC) systems and systems and methods for
performing diagnostics thereof. In general, HVAC systems include
multiple components that are designed to condition an interior
space. Conditioning requirements set for the HVAC system may be
higher in certain seasons. For example, in summer, occupants of the
interior space may request more cooling and/or dehumidification
than during spring and/or fall seasons. Additionally, in winter,
occupants of the interior space may request more heating and/or
more humidification than during spring and/or fall. As such, the
HVAC system may be inspected seasonally to increase efficiency and
reliability with which components of the HVAC system will operate
during the certain seasons. Moreover, as discussed above,
components of the HVAC system may benefit from routine inspections
at any time of the year to increase efficiency of the HVAC system
and to identify possible deviations in operation before repair or
replacement of the components is required.
[0016] To facilitate diagnostics of the components of the HVAC
system, a controller may monitor various operating parameters of
the HVAC system. For example, the operating parameters may include
an indoor air pressure, plenum or duct air pressure, an outdoor air
temperature, a return air temperature, electronic expansion valve
(EEV) data, air flow rates, outdoor fan data, power usage data, or
other parameters related to the HVAC system. The controller may
store current values of the operating parameters in a database
(e.g., electronic database, cloud database) for later access.
Moreover, the controller may compare a current value of an
operating parameter to an expected value for the operating
parameter. For example, a control or a baseline reading may be
taken for each HVAC component on a test bench. Then, based on a
comparison of the current value to its respective expected value,
the controller may determine whether the current value is outside
an expected value range. If the expected value is outside the
expected value range, the controller may proceed to initiate a
diagnostic mode. As discussed in more detail below, the controller
collects diagnostic data associated with the HVAC system while in
the diagnostic mode. The controller may additionally transmit the
diagnostic data to a service center, such that the service center
is informed and able to identify and/or perform any proposed
maintenance actions for the HVAC components.
[0017] Turning now to the drawings, FIG. 1 illustrates a heating,
ventilating, and air conditioning (HVAC) system for building
environmental management that may employ one or more HVAC units. In
the illustrated embodiment, a building 10 is air conditioned by a
system that includes an HVAC unit 12. The building 10 may be a
commercial structure or a residential structure. As shown, the HVAC
unit 12 is disposed on the roof of the building 10; however, the
HVAC unit 12 may be located in other equipment rooms or areas
adjacent the building 10. The HVAC unit 12 may be a single package
unit containing other equipment, such as a blower, integrated air
handler, and/or auxiliary heating unit. In other embodiments, the
HVAC unit 12 may be part of a split HVAC system, such as the system
shown in FIG. 3, which includes an outdoor HVAC unit 58 and an
indoor HVAC unit 56.
[0018] The HVAC unit 12 is an air cooled device that implements a
refrigeration cycle to provide conditioned air to the building 10.
Specifically, the HVAC unit 12 may include one or more heat
exchangers across which an air flow is passed to condition the air
flow before the air flow is supplied to the building. In the
illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU)
that conditions a supply air stream, such as environmental air
and/or a return air flow from the building 10. After the HVAC unit
12 conditions the air, the air is supplied to the building 10 via
ductwork 14 extending throughout the building 10 from the HVAC unit
12. For example, the ductwork 14 may extend to various individual
floors or other sections of the building 10. In certain
embodiments, the HVAC unit 12 may be a heat pump that provides both
heating and cooling to the building with one refrigeration circuit
configured to operate in different modes. In other embodiments, the
HVAC unit 12 may include one or more refrigeration circuits for
cooling an air stream and a furnace for heating the air stream.
[0019] A control device 16, one type of which may be a thermostat,
may be used to designate the temperature of the conditioned air.
The control device 16 also may be used to control the flow of air
through the ductwork 14. For example, the control device 16 may be
used to regulate operation of one or more components of the HVAC
unit 12 or other components, such as dampers and fans, within the
building 10 that may control flow of air through and/or from the
ductwork 14. In some embodiments, other devices may be included in
the system, such as pressure and/or temperature transducers or
switches that sense the temperatures and pressures of the supply
air, return air, and so forth. Moreover, the control device 16 may
include computer systems that are integrated with or separate from
other building control or monitoring systems, and even systems that
are remote from the building 10.
[0020] FIG. 2 is a perspective view of an embodiment of the HVAC
unit 12. In the illustrated embodiment, the HVAC unit 12 is a
single package unit that may include one or more independent
refrigeration circuits and components that are tested, charged,
wired, piped, and ready for installation. The HVAC unit 12 may
provide a variety of heating and/or cooling functions, such as
cooling only, heating only, cooling with electric heat, cooling
with dehumidification, cooling with gas heat, or cooling with a
heat pump. As described above, the HVAC unit 12 may directly cool
and/or heat an air stream provided to the building 10 to condition
a space in the building 10.
[0021] As shown in the illustrated embodiment of FIG. 2, a cabinet
24 encloses the HVAC unit 12 and provides structural support and
protection to the internal components from environmental and other
contaminants. In some embodiments, the cabinet 24 may be
constructed of galvanized steel and insulated with aluminum foil
faced insulation. Rails 26 may be joined to the bottom perimeter of
the cabinet 24 and provide a foundation for the HVAC unit 12. In
certain embodiments, the rails 26 may provide access for a forklift
and/or overhead rigging to facilitate installation and/or removal
of the HVAC unit 12. In some embodiments, the rails 26 may fit into
"curbs" on the roof to enable the HVAC unit 12 to provide air to
the ductwork 14 from the bottom of the HVAC unit 12 while blocking
elements such as rain from leaking into the building 10.
[0022] The HVAC unit 12 includes heat exchangers 28 and 30 in fluid
communication with one or more refrigeration circuits. Tubes within
the heat exchangers 28 and 30 may circulate refrigerant (for
example, R-410A, steam, or water) through the heat exchangers 28
and 30. The tubes may be of various types, such as multichannel
tubes, conventional copper or aluminum tubing, and so forth.
Together, the heat exchangers 28 and 30 may implement a thermal
cycle in which the refrigerant undergoes phase changes and/or
temperature changes as it flows through the heat exchangers 28 and
30 to produce heated and/or cooled air. For example, the heat
exchanger 28 may function as a condenser where heat is released
from the refrigerant to ambient air, and the heat exchanger 30 may
function as an evaporator where the refrigerant absorbs heat to
cool an air stream. In other embodiments, the HVAC unit 12 may
operate in a heat pump mode where the roles of the heat exchangers
28 and 30 may be reversed. That is, the heat exchanger 28 may
function as an evaporator and the heat exchanger 30 may function as
a condenser. In further embodiments, the HVAC unit 12 may include a
furnace for heating the air stream that is supplied to the building
10. While the illustrated embodiment of FIG. 2 shows the HVAC unit
12 having two of the heat exchangers 28 and 30, in other
embodiments, the HVAC unit 12 may include one heat exchanger or
more than two heat exchangers.
[0023] The heat exchanger 30 is located within a compartment 31
that separates the heat exchanger 30 from the heat exchanger 28.
Fans 32 draw air from the environment through the heat exchanger
28. Air may be heated and/or cooled as the air flows through the
heat exchanger 28 before being released back to the environment
surrounding the rooftop unit 12. A blower assembly 34, powered by a
motor 36, draws air through the heat exchanger 30 to heat or cool
the air. The heated or cooled air may be directed to the building
10 by the ductwork 14, which may be connected to the HVAC unit 12.
Before flowing through the heat exchanger 30, the conditioned air
flows through one or more filters 38 that may remove particulates
and contaminants from the air. In certain embodiments, the filters
38 may be disposed on the air intake side of the heat exchanger 30
to prevent contaminants from contacting the heat exchanger 30.
[0024] The HVAC unit 12 also may include other equipment for
implementing the thermal cycle. Compressors 42 increase the
pressure and temperature of the refrigerant before the refrigerant
enters the heat exchanger 28. The compressors 42 may be any
suitable type of compressors, such as scroll compressors, rotary
compressors, screw compressors, or reciprocating compressors. In
some embodiments, the compressors 42 may include a pair of hermetic
direct drive compressors arranged in a dual stage configuration 44.
However, in other embodiments, any number of the compressors 42 may
be provided to achieve various stages of heating and/or cooling. As
may be appreciated, additional equipment and devices may be
included in the HVAC unit 12, such as a solid-core filter drier, a
drain pan, a disconnect switch, an economizer, pressure switches,
phase monitors, and humidity sensors, among other things.
[0025] The HVAC unit 12 may receive power through a terminal block
46. For example, a high voltage power source may be connected to
the terminal block 46 to power the equipment. The operation of the
HVAC unit 12 may be governed or regulated by a control board 48.
The control board 48 may include control circuitry connected to a
thermostat, sensors, and alarms (one or more being referred to
herein separately or collectively as the control device 16). The
control circuitry may be configured to control operation of the
equipment, provide alarms, and monitor safety switches. Wiring 49
may connect the control board 48 and the terminal block 46 to the
equipment of the HVAC unit 12.
[0026] FIG. 3 illustrates a residential heating and cooling system
50, also in accordance with present techniques. The residential
heating and cooling system 50 may provide heated and cooled air to
a residential structure, as well as provide outside air for
ventilation and provide improved indoor air quality (IAQ) through
devices such as ultraviolet lights and air filters. In the
illustrated embodiment, the residential heating and cooling system
50 is a split HVAC system. In general, a residence 52 conditioned
by a split HVAC system may include refrigerant conduits 54 that
operatively couple the indoor unit 56 to the outdoor unit 58. The
indoor unit 56 may be positioned in a utility room, an attic, a
basement, and so forth. The outdoor unit 58 is typically situated
adjacent to a side of residence 52 and is covered by a shroud to
protect the system components and to prevent leaves and other
debris or contaminants from entering the unit. The refrigerant
conduits 54 transfer refrigerant between the indoor unit 56 and the
outdoor unit 58, typically transferring primarily liquid
refrigerant in one direction and primarily vaporized refrigerant in
an opposite direction.
[0027] When the system shown in FIG. 3 is operating as an air
conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a
condenser for re-condensing vaporized refrigerant flowing from the
indoor unit 56 to the outdoor unit 58 via one of the refrigerant
conduits 54. In these applications, a heat exchanger 62 of the
indoor unit functions as an evaporator. Specifically, the heat
exchanger 62 receives liquid refrigerant (which may be expanded by
an expansion device, not shown) and evaporates the refrigerant
before returning it to the outdoor unit 58.
[0028] The outdoor unit 58 draws environmental air through the heat
exchanger 60 using a fan 64 and expels the air above the outdoor
unit 58. When operating as an air conditioner, the air is heated by
the heat exchanger 60 within the outdoor unit 58 and exits the unit
at a temperature higher than it entered. The indoor unit 56
includes a blower or fan 66 that directs air through or across the
indoor heat exchanger 62, where the air is cooled when the system
is operating in air conditioning mode. Thereafter, the air is
passed through ductwork 68 that directs the air to the residence
52. The overall system operates to maintain a desired temperature
as set by a system controller. When the temperature sensed inside
the residence 52 is higher than the set point on the thermostat
(plus a small amount), the residential heating and cooling system
50 may become operative to refrigerate additional air for
circulation through the residence 52. When the temperature reaches
the set point (minus a small amount), the residential heating and
cooling system 50 may stop the refrigeration cycle temporarily.
[0029] The residential heating and cooling system 50 may also
operate as a heat pump. When operating as a heat pump, the roles of
heat exchangers 60 and 62 are reversed. That is, the heat exchanger
60 of the outdoor unit 58 will serve as an evaporator to evaporate
refrigerant and thereby cool air entering the outdoor unit 58 as
the air passes over outdoor the heat exchanger 60. The indoor heat
exchanger 62 will receive a stream of air blown over it and will
heat the air by condensing the refrigerant.
[0030] In some embodiments, the indoor unit 56 may include a
furnace system 70. For example, the indoor unit 56 may include the
furnace system 70 when the residential heating and cooling system
50 is not configured to operate as a heat pump. The furnace system
70 may include a burner assembly and heat exchanger, among other
components, inside the indoor unit 56. Fuel is provided to the
burner assembly of the furnace 70 where it is mixed with air and
combusted to form combustion products. The combustion products may
pass through tubes or piping in a heat exchanger (that is, separate
from heat exchanger 62), such that air directed by the blower 66
passes over the tubes or pipes and extracts heat from the
combustion products. The heated air may then be routed from the
furnace system 70 to the ductwork 68 for heating the residence
52.
[0031] FIG. 4 is an embodiment of a vapor compression system 72
that can be used in any of the systems described above. The vapor
compression system 72 may circulate a refrigerant through a circuit
starting with a compressor 74. The circuit may also include a
condenser 76, an expansion valve(s) or device(s) 78, and an
evaporator 80. The vapor compression system 72 may further include
a control panel 82 that has an analog to digital (A/D) converter
84, a microprocessor 86, a non-volatile memory 88, and/or an
interface board 90. The control panel 82 and its components may
function to regulate operation of the vapor compression system 72
based on feedback from an operator, from sensors of the vapor
compression system 72 that detect operating conditions, and so
forth.
[0032] In some embodiments, the vapor compression system 72 may use
one or more of a variable speed drive (VSDs) 92, a motor 94, the
compressor 74, the condenser 76, the expansion valve or device 78,
and/or the evaporator 80. The motor 94 may drive the compressor 74
and may be powered by the variable speed drive (VSD) 92. The VSD 92
receives alternating current (AC) power having a particular fixed
line voltage and fixed line frequency from an AC power source, and
provides power having a variable voltage and frequency to the motor
94. In other embodiments, the motor 94 may be powered directly from
an AC or direct current (DC) power source. The motor 94 may include
any type of electric motor that can be powered by a VSD or directly
from an AC or DC power source, such as a switched reluctance motor,
an induction motor, an electronically commutated permanent magnet
motor, or another suitable motor.
[0033] The compressor 74 compresses a refrigerant vapor and
delivers the vapor to the condenser 76 through a discharge passage.
In some embodiments, the compressor 74 may be a centrifugal
compressor. The refrigerant vapor delivered by the compressor 74 to
the condenser 76 may transfer heat to a fluid passing across the
condenser 76, such as ambient or environmental air 96. The
refrigerant vapor may condense to a refrigerant liquid in the
condenser 76 as a result of thermal heat transfer with the
environmental air 96. The liquid refrigerant from the condenser 76
may flow through the expansion device 78 to the evaporator 80.
[0034] The liquid refrigerant delivered to the evaporator 80 may
absorb heat from another air stream, such as a supply air stream 98
provided to the building 10 or the residence 52. For example, the
supply air stream 98 may include ambient or environmental air,
return air from a building, or a combination of the two. The liquid
refrigerant in the evaporator 80 may undergo a phase change from
the liquid refrigerant to a refrigerant vapor. In this manner, the
evaporator 38 may reduce the temperature of the supply air stream
98 via thermal heat transfer with the refrigerant. Thereafter, the
vapor refrigerant exits the evaporator 80 and returns to the
compressor 74 by a suction line to complete the cycle.
[0035] In some embodiments, the vapor compression system 72 may
further include a reheat coil in addition to the evaporator 80. For
example, the reheat coil may be positioned downstream of the
evaporator relative to the supply air stream 98 and may reheat the
supply air stream 98 when the supply air stream 98 is overcooled to
remove humidity from the supply air stream 98 before the supply air
stream 98 is directed to the building 10 or the residence 52.
[0036] It should be appreciated that any of the features described
herein may be incorporated with the HVAC unit 12, the residential
heating and cooling system 50, or other HVAC systems. Additionally,
while the features disclosed herein are described in the context of
embodiments that directly heat and cool a supply air stream
provided to a building or other load, embodiments of the present
disclosure may be applicable to other HVAC systems as well. For
example, the features described herein may be applied to mechanical
cooling systems, free cooling systems, chiller systems, or other
heat pump or refrigeration applications.
[0037] As discussed above, the present techniques are directed to a
control system for monitoring operating parameters and performing
automated diagnostics for components of an HVAC system. For
example, the control device 16 discussed above may be part of a
control system that monitors current values of operating parameters
of the components. The control device 16 may compare current values
to respective expected value ranges for each operating parameter to
determine if the current values are outside the respective expected
value ranges. Then, the control device 16 may initiate a diagnostic
mode if the control device 16 determines that one or more of the
current values are outside the expected value ranges. In the
diagnostic mode, the control device 16 may gather diagnostic data
that is utilized to identify proposed maintenance actions for the
components. Moreover, the control device 16 may communicate with
computer systems that are integrated with or separate from other
building control or monitoring systems, including systems that are
remote from the building. For example, the control device 16 may
transmit the diagnostic data and/or alerts to one or more service
centers. The service center may include one or more user interfaces
or controllers to enable determination of proposed maintenance
actions for the components. Additionally, the service center may
include technical service personnel that may perform the proposed
maintenance actions for the one or more components. Further, the
control device 16 may store the expected value ranges of the
parameters and/or receive the expected value ranges in real time.
In some embodiments, the service center determines the expected
value ranges on a test bench and provides the expected value ranges
to the control device 16 as a control or baseline. As such, the
present techniques discussed in detail below enable an HVAC system
to run more efficiently and more reliably than systems without
control systems having the automated diagnostics features described
herein.
[0038] FIG. 5 is a schematic illustrating a control system 100
having a controller 102 for monitoring components of an HVAC system
104. In some embodiments, the HVAC system 104 may encompass or
include the HVAC unit 12 discussed above, the residential heating
and cooling system 50 discussed above, and/or other HVAC systems.
Moreover, the HVAC system 104 may perform all or a combination of
heating, ventilation, and/or air conditioning functions. As shown,
the HVAC system 104 includes HVAC components 108. The HVAC
components 108 may be any of the above mentioned components of the
HVAC unit 12, the residential heating and cooling system 50, or
other components discussed above and/or below. As will be
understood, the present techniques may include particular utility
for residential systems, such that service centers associated with
the HVAC system 104 are more quickly informed about deviations in
performance of the HVAC components 108. As such, technical service
personnel of the service center may be capable of arriving at a
residence having the HVAC system 104 more quickly and with any
desired tools or parts, such that maintenance actions may be
completed more efficiently.
[0039] Moreover, in some embodiments, the controller 102 is, or may
be a component of, the control device 16 or the interface board 90
discussed above. The controller 102 includes a memory 101 for
storing data and instructions and a processor 103 for execution of
the techniques disclosed herein. As shown, the controller 102
communicates with many elements of the control system 100 to
monitor the HVAC components 108. For example, the controller 102
transmits and/or receives signals from a sensor array 110, a
service center 114, and a user interface 120. By communicating with
and controlling the HVAC system 104, the control system 100
facilitates automated diagnostics thereof. As shown, the controller
102 may wirelessly communicate to the other components of the
control system 100 through wireless connections, such as a
connection through a cellular network, radio transmission,
Bluetooth.RTM. Low Energy, ZigBee.RTM., WiFi.RTM., or another time
of wireless communication. Moreover, in some embodiments, the
controller 102 and the other components may communicate and
transmit data through wired connections.
[0040] As shown, the controller 102 receives transmits and/or
receives signals from a sensor array 110. The sensor array 110 may
include one sensor 112 or multiple sensors 112. In some
embodiments, the sensors 112 of the sensor array 110 are disposed
on or near the HVAC components 108. In some embodiments, the
sensors 112 are positioned near inlet regions and/or outlet regions
of the HVAC components 108. As such, the sensors 112 may transmit
signals to the controller 102 that are indicative of operating
parameters of the HVAC components 108. The sensors 112 may transmit
the signals indicative of the operating parameters at regular
intervals to the controller 102, upon instruction by the controller
102, and/or when the operating parameters related to a respective
component of the HVAC components 108 has changed. The sensors 112
may be any suitable type of sensor for monitoring the operating
parameters of the HVAC components 108, including pressure sensors,
temperature sensors, flow sensors, EEV sensors, voltage sensors,
vibration sensors, stress sensors, among others.
[0041] By way of an example, sensors 112 may be disposed near the
heat exchanger 62 (FIG. 3) to monitor a flow of refrigerant
therein. The sensors 112 may thus transmit signals to the
controller 102 indicative of the flow of refrigerant in the heat
exchanger 62. The sensors 112 may transmit the signals each time a
predefined period of time (e.g., 1 second, 30 seconds, 5 minutes,
60 minutes, etc.) has passed. Additionally or alternatively, the
sensors 112 may transmit the signals based on a request from the
controller 102. That is, upon instruction from the controller 102,
the sensors 112 may transmit signals indicative of the flow of
refrigerant in the heat exchanger 62. Moreover, the sensors 112 may
transmit a signal when the flow of refrigerant changes (e.g.,
beyond a change threshold). For example, the sensors 112 may
transmit a signal indicative of an initial flow of the refrigerant
when the control system 100 is first turned on. Then, the sensors
112 may not transmit signals for as long as the flow of refrigerant
is substantially the same as (e.g., within a range from, within a
percentage difference from) the initial flow of the refrigerant.
When the flow of refrigerant changes, the sensors 112 may then
transmit a signal indicative of a current flow of the refrigerant.
By receiving the signals from the sensors 112 in real time, the
controller 102 may thus determine the flow of the refrigerant in
the heat exchanger 62 or be able to accurately estimate (e.g.,
interpolate, extrapolate) the flow during all operation of the HVAC
system 104.
[0042] It is to be understood that the operation of the sensors 112
may be extended to all HVAC components 108 and all operating
parameters thereof. That is, in some embodiments, the sensors 112
transmit signals indicative of operating parameters that include
pressures, temperatures, leaving air temperature, EEV data,
airflows, outdoor fan data, incoming power data, and the like. In
some embodiments, the operating parameters include each parameter
of the residential heating and cooling system 50 that the
controller 102 is able to monitor. Moreover, the sensors 112 may
each include wireless or wired connections to the controller 102.
In some embodiments, application of the present techniques includes
adding new sensors 112 to a preexisting sensor array 110 and/or
adding communication functions to existing sensors 112.
[0043] Moreover, the sensors 112 may transmit signals indicative of
status indicators for certain HVAC components 108. In such
embodiments, status indicators are to be understood to be another
type of operating parameter. For example, the status indicators may
indicate whether the HVAC components 108 have a healthy status, a
fault status, an online status, and/or an offline status. In some
embodiments, the controller 102 receives signals from sensors 112
indicative of the status indicators for each HVAC component 108.
For example, one of the sensors 112 may indicate that the furnace
system 70 is offline. Then, when the residential heating and
cooling system 50 starts the furnace system 70, the sensor 112 may
indicate that the furnace system 70 has an online status and a
healthy status. In certain embodiments, if instead of turning on,
the furnace system 70 misfires, the controller 102 may identify
that the status indicator for the furnace system 70 includes a
fault status and/or an offline status. In such embodiments, the
controller 102 may monitor the status indicators to determine
whether components are healthy or in need of maintenance.
[0044] To enable automated diagnostics, the sensors 112 transmit
the current values of operating parameters, such as operating data,
current operating data, and/or status indicators, to the controller
102. By receiving the current values of the operating parameters,
the controller 102 may monitor the operation of the HVAC components
108. Additionally, the controller 102 may store the current values
of the operating parameters as stored values of the operating
parameters in a memory, a database, a cloud database, a hard drive,
or in another suitable electronic or physical form. The controller
102 may therefore operate as a historian component of the control
system 100. Moreover, in some embodiments, the controller 102 is
able to access, view, and utilize the stored operating parameters
for performing automated diagnostics. The controller 102 may also
enable operators to view organized views of the stored operating
parameters, such as timelines of the operating data organized by
component, environmental conditions, and/or detected errors, among
others.
[0045] Moreover, the controller 102 communicates with the service
center 114. The controller 102 may receive signals from and
transmit signals to the service center 114 to enable automated
diagnostics of the HVAC components 108. The service center 114 may
house technical service personnel who specialized in performing
maintenance actions for the HVAC components 108. For example, the
service center 114 may communicate with multiple controllers 102 of
multiple HVAC systems 104. In some embodiments, the service center
114 communicates with each controller 102 in a geographical region
(e.g., town, county, state, etc.) and/or each controller 102
associated with certain types of equipment (e.g., model of
residential HVAC systems, HVAC systems having a furnace system,
HVAC systems having a heat pump, etc.). In some embodiments, the
HVAC system 104 and/or the controller 102 may have been installed
in the residence 52 (FIG. 3) by the technical service personnel of
the service center 114. As such, the service center 114 may include
specialized diagnostic equipment, a service controller 116, and
replacement parts for the HVAC components 108 to enable performance
of maintenance actions.
[0046] Further, the service center 114 may determine baseline data
for the HVAC components 108 during a baseline test. That is, the
service center 114 may perform a baseline test to monitor test
components that correspond to the HVAC components 108. For example,
in some embodiments, the test components correspond to the HVAC
components 108 by having the same or similar product models as the
HVAC components 108, the same or similar operating characteristics
as the HVAC components, and the like.
[0047] In some embodiments, the service center 114 monitors the
test components through baseline tests performed over various
testing operating conditions. The various testing operating
conditions may include ranges and subsets of operating conditions
that the HVAC components 108 of the HVAC system 104 may experience.
In some embodiments, the testing operating conditions may include
all, or a substantial (e.g., major) portion, of the operating
conditions that the HVAC components 108 may experience. In some
embodiments, the service center 114 may include sensors enabled to
transmit data to the service controller 116 that is indicative of
the performance of the test components in the various testing
operating conditions. Thus, the service controller 116 of the
service center 114 may collect values of parameters indicative of
the operation of the test components throughout the testing
operating conditions. Moreover, the service controller 116 may
extrapolate, interpolate, or otherwise determine parameters
indicative of operation of the test components through an extended
range of operating conditions based on the collected values of
testing operating parameters.
[0048] For example, the test components may include a test blower
similar or identical to the blower 66 (FIG. 3). In some
embodiments, performance of the test blower is monitored over all
or a portion of the temperatures, pressures, and flowrates that the
test blower may experience or generate. In some embodiments, one
operating parameter is varied during the baseline test of the test
blower at a time, such that various relationships are determined
for how each operating parameter relates to one another. For
example, the baseline test may be performed by holding all other
variables constant while the temperature is varied, while changes
in the performance of the test blower are closely monitored to
determine the effect of changing temperature on the other
variables. The baseline test process may be repeated for each
variable or set of variables that are independent from a remaining
portion of the variables. Additionally, the baseline test may be
repeated for each major process (e.g. compression, evaporation,
condensation etc.) of the HVAC system 104 or each component
therein.
[0049] As a result, the service center 114 collects baseline data
for the test components that may be used to determine an expected
value range for the operating parameters of the HVAC components
108. The expected value range may be determined individually for
each HVAC component 108 or for each parameter of the HVAC
components 108. For example, the service center 114 may determine
via a baseline test that during certain environmental conditions,
the power usage of the fan 64 (FIG. 3) normally ranges between 400
and 500 Watts. As such, the service center 114 may set an expected
value range for an operating parameter for power usage of the fan
64 based on the baseline data produced by the baseline test. The
expected value range may be set as the baseline data, as a
predefined value difference from the baseline data, as a percentage
difference from the baseline data, or as another suitable
relationship relative to the baseline data. For example, the
service center 114 may determine that power usages of the fan 64
within 10% of the normal range of 400 to 500 Watts observed during
the baseline test are within a respective expected value range.
[0050] In some embodiments, the service center 114 may individually
determine the expected value range for each operating parameter
and/or for component. For example, the expected value range for
power usage of the fan 64 may be broader than an expected value
range for temperature of refrigerant in the heat exchanger 62 (FIG.
3). In such embodiments, the expected value range for the power
usage may be embodied by a ten percent difference from respective
baseline data, while the expected value range for the temperature
of the refrigerant may be embodied by a five percent difference
from respective data. It is to be understood, however, that any
suitable expected value range may be set for each operating
parameter of the HVAC system 104. Indeed, some expected value
ranges may be defined by a percentage difference or deviation above
the respective baseline data, while other expected value ranges are
defined by a percentage difference or deviation below the
respective baseline data.
[0051] As such, the baseline data collected from the test
components may be used to determine the expected value ranges used
to quantify how the HVAC components 108 of the residence 52 are
operating. In some embodiments, the expected value ranges for each
parameter of each HVAC component 108 is transmitted from the
service center 114 to the controller 102. However, the expected
value ranges may be installed in the controller 102 by the
technical service personnel of the service center 114, or the
service center 114 may transmit the baseline data to the controller
102, which may locally determine the expected value ranges from the
baseline data. In some embodiments, the baseline data is
continuously updated to include new test components correlating to
new HVAC components 108, such that the baseline data covers all
known components of the HVAC system 104. However, the service
center 114 and/or the controller 102 may also extrapolate,
interpolate, or otherwise suitably determine an expected value
range for components that do not include actual baseline data. For
example, if baseline data is available for a component that is
similar to an HVAC component 108 of the HVAC system 104, the
service center 114, or the controller 102 may duplicate and utilize
the data as baseline data for the actual HVAC component 108. In
such embodiments, a degree of certainty may be accounted for the
duplicated baseline data by the expected value range determined
therefrom, such that the expected value range includes a larger
range or larger margin of error for the duplicated data.
[0052] In certain embodiments, the controller 102 automatically
monitors operation of the HVAC components 108 by comparing the
current values of operating parameters to respective expected value
ranges for the operating parameters. In some embodiments, the
controller 102 may compare each current value as it is received to
the expected value ranges. Then, the controller 102 determines if
the current value is inside or outside of the expected value range.
If the parameter is inside the range, the controller 102 may
proceed to continue monitoring the HVAC components 108.
[0053] Based on a determination that one or more current values are
outside respective expected value ranges, the controller 102 may
initiate a diagnostic mode. The diagnostic mode may be initiated or
triggered based on a determination that a certain number of current
values of parameters are outside the respective expected value
range. In addition, the controller 102 may be enabled to perform
different types of diagnostic modes based on which components or
what quantity of components have current values of operating
parameters outside the respective expected value ranges. As such,
based on the automatic receipt of the current values and
determination of whether the current values are outside respective
expected value ranges, the controller 102 automatically initiates
the diagnostic mode to collect diagnostic data for identifying
proposed maintenance actions.
[0054] In the diagnostic mode, the controller 102 may collect
certain diagnostic data and transmit the diagnostic data to the
service center 114. The diagnostic data may include a comprehensive
series of data points, such as pressures, outdoor air temperature,
return or supply air temperature, EEV data, air flow rates, outdoor
fan data, incoming power data, and/or any other data collectable by
the control system 100. The diagnostic data from the controller 102
may then be transmitted to the service center 114 or uploaded to a
cloud for the service center 114 to view. Additionally, in some
embodiments, the controller 102 may send the diagnostic data to the
service center 114 when a certain time period of diagnostic data or
amount of diagnostic data (e.g., 5 minutes, 1 hour, 10 sample
points, 20 sample points, 100 sample points, etc.) is collected. In
some embodiments, the controller 102 transmits the diagnostic data
as soon as a data point is collected for each HVAC component 108 or
a desired subset of the HVAC components 108. Moreover, the
diagnostic data may be transmitted as soon as the diagnostic mode
is determined to be complete. Upon completion of collecting the
diagnostic data, the controller 102 may turn off the diagnostic
mode. Additionally, if a portion of the diagnostic data is not able
to be collected, the controller 102 may terminate the diagnostic
mode and store an indication of which diagnostic data was not able
to be collected.
[0055] In some embodiments, the controller 102 may initiate various
types of diagnostic modes based on the quantity and/or type of HVAC
components 108 that have deviated from the respective expected
value baselines. For example, the controller 102 may initiate an
extreme diagnostic mode if at least a threshold quantity of the
HVAC components 108 has deviated from the respective expected value
baselines. Additionally or alternatively, the controller 102 may
initiate the extreme diagnostic mode if certain HVAC components
(e.g., blower 66, furnace system 70, and heat exchangers 60, 62,
etc.) of the HVAC components 108 have deviated from the respective
expected value baselines. In the extreme diagnostic mode, the
controller 102 may collect diagnostic data at a greater
resolution/frequency and/or for a longer period of time than in a
standard diagnostic mode. Moreover, the controller 102 may
additionally or alternatively be configured to send an alert to the
service center 114 indicative of the initiation of the extreme
diagnostic mode, such that the service center 114 may be
immediately or near immediately informed of any potential issues to
enable rapid identification of proposed maintenance actions.
[0056] Additionally, the controller 102 may initiate a lesser
diagnostic mode if only one HVAC component 108 has deviated from
the respective expected value baseline and/or if only certain HVAC
components 108 (e.g., ductwork 68, refrigerant conduits 54) of the
HVAC components 108 have deviated from the expected value
baselines. In some embodiments, the lesser diagnostic mode collects
diagnostic data at a lower resolution/frequency and/or for a lesser
period of time than in the standard diagnostic mode. Moreover, in
some embodiments of the lesser diagnostic mode, the controller 102
may store diagnostic data collected therefrom instead of
transmitting the diagnostic data to the service center 114. In such
embodiments, the diagnostic data may still be available for viewing
or analysis upon request. As such, the controller 102 may be
enabled to maintain memory and processing ability for performing
subsequent standard and/or extreme diagnostic modes. It is to be
understood that the various types of diagnostic modes may be
configured based on characteristics of the HVAC system 104 (e.g.,
memory, processing power, components, and associated service center
114) and/or the user of the HVAC system 104.
[0057] Thus, based on the diagnostic data associated with the HVAC
system 104, the service center 114 is enabled to identify proposed
maintenance actions. For example, based on the diagnostic data, the
service center 114 may analyze, diagnose, and repair any potential
faults detected by the controller 102. To enable the service center
114 to better access the diagnostic data, the diagnostic data may
be categorized based on various properties associated with the HVAC
system 104. For example, the diagnostic data may be categorized
within a database based on the type or qualities of the residence
52, the location of the residence 52, the types of components
included in the HVAC system 104, environmental qualities
(temperature, pressure, precipitation, salt content, humidity,
elevation, etc.) associated with the location of the residence,
identification data related to the controller 102, identification
data or qualifications related to technical service personnel of
the service center 114 associated with the controller 102, or the
like. Thus, the service controller 116 or the personnel of the
service center 114 may be able to access the diagnostic data and
corresponding issues that have occurred in similar residences or
HVAC system 104 to quickly and accurately identify proposed
maintenance actions for the HVAC system 104.
[0058] In some embodiments, the service center 114 may initiate a
diagnostic mode on the HVAC system 104. For example, if similar
HVAC systems 104 in the same environment as the HVAC system 104 are
experiencing parameters outside of expected value ranges, the
service center 114 may request that the controller 102 enters a
diagnostic mode. That is, if a predetermined quantity of other HVAC
systems 104 within a predefined distance of the HVAC system 104
have initiated diagnostic modes, the service center 114 may
instruct the controller 102 to perform a diagnostic mode. Thus, the
service center 114 may inform the user of the HVAC system 104 to
modify operation of the HVAC system 104 to preemptively keep the
system running smoothly.
[0059] In some embodiments, the diagnostic data is taken at an
increased rate relative to the operating data. Additionally or
alternatively, the diagnostic data may be sampled for more
operating parameters than the operating data. That is, the
diagnostic data may include more information about operation of the
HVAC system 104 than the operating data, such that a higher
resolution and/or greater depth of information are collected in the
diagnostic data. Additionally, the HVAC system 104 may
automatically initiate and complete a diagnostic mode a predefined
quantity of times per year. Moreover, the HVAC system 104 may
perform the diagnostic mode at least once before each summer season
and at least one before each winter season to ensure operation of
the HVAC system 104 is checked before heavy heating and cooling
seasons (e.g., high-HVAC-stress seasons) begin. In some
embodiments, the HVAC system 104 may perform the diagnostic mode a
predefined quantity of time after the last diagnostic mode was
complete, such that current diagnostic data is regularly available
for the HVAC system 104. Each of these quantities of time may be
user set or set by the service center 114. Additionally, the
diagnostic data is uploaded and stored in the controller 102 and/or
the service center 114 such that the data may be readily reviewed.
As such, the techniques disclosed herein enable multiple residences
to be checked for proper operation before winter and/or summer
seasons begin, thus reducing a workload of repair requests made to
the service center 114.
[0060] The diagnostic data may additionally include a list of any
previous or current status indicators of the operating data of the
HVAC system 104. For each fault status, the controller 102 or the
service center 114 may identify which HVAC components 108 or groups
of HVAC components 108 (e.g., hierarchal arrangement) contributed
to the fault status. Additionally, such calculations may include a
determination of a degree of certainty that the HVAC components 108
are responsible for the fault status. Moreover, the service center
114 may analyze the list of status indicators in the service center
114 along with the other operating data to predict any future
deviations from the expected value range. The predicted deviations
may include a prediction of how likely it is that the deviation
will occur. In some embodiments, one or all of such determinations
are made from the diagnostic data. Additionally, the predicted
deviations may include values of operating parameters that are
beyond the respective expected value thresholds, status indicators
that indicate a fault status or indicate an offline status when an
online status was requested, or other suitable predictions made
from the data acquired herein. In some embodiments, the status
indicators respectively indicate whether each HVAC component
includes a healthy status or a fault status, such that the healthy
status is indicated by respective current values within the
expected value range, and the fault status is indicated by
respective current values outside of the expected value range.
[0061] In some embodiments, the service center 114 analyzes the
diagnostic data to determine whether any HVAC components 108 are in
need repair or replacement. Thus, the service center 114 can
coordinate with the user of the HVAC system 104 to schedule
proposed maintenance actions to perform the repair or replacement.
Additionally, the technical service personnel may arrive at the
residence 52 having the HVAC system 104 with any desired tools or
parts. As such, the automatic diagnostics procedure reduces
operator trips and increases knowledge available to both the
service center and the user of the HVAC system 104.
[0062] Moreover, the controller 102 may be communicatively coupled
to a user interface 120. The user interface 120 may include a
display 122 to display information to a user of the controller 102.
In certain embodiments, the display 122 and the user interface 120
are within the residence 52 and/or integral with the controller
102, though in other embodiments, the user interface 120 and the
display 122 may be part of a mobile device, laptop, tablet, smart
TV, or the like. As will be discussed in more detail below, the
user interface 120 may receive instruction from the controller 102
and/or the service center 114 to display certain information or
alerts to the user. Additionally, the user interface 120 may also
receive input from the user to send instructions and/or alerts to
the controller 102 and/or service center 114.
[0063] In some embodiments, via the user interface 120, the user of
the HVAC system 104 may set user settings to indicate how the
service center 114 may interact with the HVAC system 104. Via the
user settings, the user may select how the controller 102 will
communicate with the service center 114. For example, the user may
select what times of the day, the week and/or the month the
controller 102 will communicate with the service center 114.
Additionally, the user may select other user settings, such as a
preferred service center, a preferred time of the day, the week,
and/or the month that proposed maintenance actions are performed.
The user may additionally select whether the technical service
personnel have permission to work on an exterior of the residence
52 and/or inside the residence 52 when the user is not home.
[0064] In some embodiments, the user interface 120 may communicate
certain actions or requests to the user. For example, the display
122 of the user interface 120 may present recommended actions or
behaviors to the user based on the operating data and/or the
diagnostic data collected during diagnostic modes. For example, if
a fault status is determined, the recommended actions or behaviors
may be designed to guard the faulted HVAC components 108 from
further damage. Such recommended actions or behaviors may include
requesting that the user to change the temperature and/or humidity
settings of the residence until technical service personnel arrive
to perform proposed maintenance actions. In some embodiments, the
user interface 120 may prompt the user to complete a questionnaire
to describe physical characteristics of the HVAC components 108.
For example, the user may describe an appearance of the HVAC
components 108, sounds made by the HVAC components 108, or other
suitably physical descriptions that typical sensors 112 of the HVAC
system 104 may not be able to collect. Moreover, through the user
interface 120, the user may be able to initiate one or more
diagnostic modes (e.g., user-initiated diagnostic mode). Upon
initiation of a user-initiated diagnostic mode, a specialized
questionnaire may be presented to the user to describe what issues
may be occurring the HVAC system 104, thus enabling the controller
102 and/or the service center 114 to more rapidly identify any
proposed maintenance actions that are targeted toward the issues of
the HVAC system 104.
[0065] FIG. 6 illustrates a flowchart of a method 150 that may be
employed to perform the diagnostic mode of the controller 102 of
FIG. 5. It is to be understood that the steps discussed herein are
merely exemplary, and certain steps may be combined, omitted, or
performed in a different order than the order discussed herein.
Moreover, although discussed with reference to the controller 102
(FIG. 5), it is to be understood that the steps may be performed by
other suitable devices, such as the controller 116 of the service
center 114, a remote device, or the like. First, the method 150 may
include determining an expected value range for each operating
parameter of the HVAC components 108 of the HVAC system 104 (block
152). For example, the expected value range may be determined based
on baseline data that is collected during a baseline test, such as
may be conducted at the service center 114. The baseline test may
monitor the operating parameters for one or more HVAC components
similar or the same as the HVAC components 108. Thus, based on the
observed baseline data, expected value ranges may be determined by
the service center 114 and provided to the controller 102 of the
HVAC system 104.
[0066] Next, the method 150 includes receiving signals indicative
of operating data of the HVAC components 108 (block 154). That is,
the controller 102 may locally monitor the operating parameters of
the HVAC components 108. The controller 102 may determine one or
more current values for the operating parameters based on signals
transmitted from sensors 112.
[0067] Additionally, the method 150 includes determining (node 156)
if a current value of an operating parameter is outside the
expected value range. If the expected value is inside the expected
value range, the controller 102 may then continue to receive and
monitor operating data. Moreover, the determination may be repeated
for each operating parameter of each component. However, the
determination may be based solely on one current value being
outside the expected value range.
[0068] If the controller determines (node 156) that the operating
parameter is outside the expected range, the controller 102 may
proceed to initiate the diagnostic mode (block 158). In such
embodiments, the method 150 may also include collecting diagnostic
data (block 160). As previously discussed, the controller 102 may
collect the diagnostic data at a greater frequency and/or for a
greater amount of time than the frequency and/or amount of time
operational data is collected. Moreover, the diagnostic mode may be
initiated based on other determinations, such as user input, passed
amounts of time, or other suitable considerations discussed above.
Moreover, the diagnostic mode may be customized for each individual
HVAC system 104 and/or service center 114.
[0069] Accordingly, the present disclosure is directed to a control
system of a HVAC system that monitors operation of the HVAC
components to selectively initiate a diagnostic mode. The
diagnostic mode is initiated based on a determination that at least
one current value of an operating parameter is outside an expected
value range. Indeed, as discussed above, the expected value range
may be determined by a service center based on baseline tests
performed on components similar to the HVAC components. In the
diagnostic mode, the controller may automatically collect and
transmit diagnostic data to the service center, such that proposed
maintenance actions may be determined and performed for the HVAC
system more efficiently compared to systems without automated
diagnostics.
[0070] While only certain features and embodiments of the present
disclosure have been illustrated and described, many modifications
and changes may occur to those skilled in the art (e.g., variations
in sizes, dimensions, structures, shapes and proportions of the
various elements, values of parameters (e.g., temperatures,
pressures, etc.), mounting arrangements, use of materials,
orientations, etc.) without materially departing from the novel
teachings and advantages of the subject matter recited in the
claims. The order or sequence of any process or method steps may be
varied or re-sequenced according to alternative embodiments. It is,
therefore, to be understood that the appended claims are intended
to cover all such modifications and changes as fall within the true
spirit of the disclosure. Furthermore, in an effort to provide a
concise description of the embodiments, all features of an actual
implementation may not have been described (i.e., those unrelated
to the presently contemplated best mode of carrying out the
disclosure, or those unrelated to enabling the claimed features).
It should be appreciated that in the development of any such actual
implementation, as in any engineering or design project, numerous
implementation specific decisions may be made. Such a development
effort might be complex and time consuming, but would nevertheless
be a routine undertaking of design, fabrication, and manufacture
for those of ordinary skill having the benefit of this disclosure,
without undue experimentation.
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