Method and device for monitoring an HVAC / r system

Abstract

Disclosed herein is a monitoring device for a heating, ventilation, air conditioning, and refrigeration (HVAC / R) system. The monitoring device includes a housing enclosing an internal cavity and input / output (I / O) ports, which are fixed relative to the housing. The I / O ports include current sensing ports, temperature sensing ports, and thermostat voltage ports. The monitoring device also includes an electronic control unit (ECU) located within the housing and in electrical communication with the I / O ports. The ECU receives a request for sensor data regarding operation of the HVAC / R system from at least one of the current sensing ports, the temperature sensing ports, or the thermostat voltage ports. The ECU is also configured to control a sensor in communication with one of the I / O ports based on the request for sensor data, collect sensor data from the sensor in communication with the I / O ports, and transmit the sensor data to a remote location.

Description

METHOD AND DEVICE FOR MONITORING AN HVAC / R SYSTEMCROSS REFERENCE TO RELATED APPLICATION

[0001] The present application claims the benefit of priority to United States Provisional Application No. 63 / 714,385 filed October 31, 2024, which is hereby incorporated by reference in its entirety.INTRODUCTION

[0002] This disclosure relates to a method and a device for monitoring a heating, ventilation, air conditioning, and refrigeration (“HVAC / R”) system, and more particularly, to a device that independently monitors operating parameters or characteristics relating to the HVAC / R system.

[0003] HVAC / R systems, particularly for commercial applications, can improve the comfort of a space for customers or can lengthen the shelf life for products stored therein. Routine maintenance of HVAC / R systems can ensure proper operation for an extended period. However, when a component of the HVAC / R system fails or operates at reduced efficiency, the system may require an unscheduled service that could take the HVAC / R system out of operation, making the space uncomfortable or resulting in the loss of product.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate implementations of the disclosure and together with the description, explain the principles of the disclosure.

[0005] FIG. l is a schematic illustration of a front view of an example monitoring device according to this disclosure.

[0006] FIG. 2 is a schematic illustration of an interior cavity of the monitoring device of FIG. 1, illustrating a printed circuit board (“PCB”).

[0007] FIG. 3 is a schematic illustration of the monitoring device of FIG. 1 connected to an example HVAC / R system.

[0008] FIG. 4 is a schematic illustration of a front view of another monitoring device according to this disclosure.

[0009] FIG. 5 is a schematic illustration of an interior cavity of the monitoring device of FIG. 4 illustrating a printed circuit board (“PCB”).

[0010] FIG. 6 is a schematic illustration of the monitoring device of FIG. 4 connected to an example HVAC / R system.

[0011] FIG. 7 is a flow diagram of an example method of operating the monitoring devices of FIG. 1 or FIG. 4.SUMMARY

[0012] Disclosed herein is a monitoring device for an HVAC / R system. The monitoring device includes a housing enclosing an internal cavity and I / O ports which are fixed relative to the housing. The I / O ports include current sensing ports, temperature sensing ports, and thermostat voltage ports. The monitoring device also includes an electronic control unit (ECU) located within the housing and in electrical communication with the input output (I / O) ports. The ECU is configured to receive a request for sensor data regarding operation of the HVAC / R system from at least one of the current sensing ports, the temperature sensing ports, or the thermostat voltage ports. The ECU is also configured to control a sensor in communication with one of the I / O ports based on the request for sensor data, collect sensor data from the sensor in communication with the I / O ports, and transmit the sensor data to a remote location.

[0013] In one aspect of the disclosure, the monitoring device includes a temperature sensor in electrical communication with the ECU through each of the plurality of temperature sensing ports.

[0014] In one aspect of the disclosure, the monitoring device includes a thermostat voltage sensor in electrical communication with the ECU through each of the plurality of thermostat voltage ports.

[0015] In one aspect of the disclosure, the monitoring device includes a current clamp in electrical communication with the ECU through each of the plurality of current sensing ports.

[0016] In one aspect of the disclosure, the current clamp includes a blower current clamp configured to determine an operational state of a blower on the HVAC / R system.

[0017] In one aspect of the disclosure, the plurality of I / O ports includes a communications port.

[0018] In one aspect of the disclosure, the monitoring device includes an antenna in electrical communication with the ECU through the communications port and the antenna is configured to transmit the sensor data collected by the ECU to the remote location.

[0019] In one aspect of the disclosure, the ECU is configured to control an operational state of an HVAC / R system.

[0020] In one aspect of the disclosure, the plurality of thermostat voltage ports includes a plurality of thermostat input ports configured to receive electrical communications from a thermostat and a plurality of thermostat output ports configured to transmit the electrical communications from the thermostat to the HVAC / R system.

[0021] In one aspect of the disclosure, the ECU is configured to control a switching assembly and the switching assembly is configured to transfer the electrical communications from the thermostat at the plurality of thermostat input ports to the HVAC / R system through the plurality of thermostat output ports when in a first mode and electrically isolate the electrical communications from the thermostat to the plurality of thermostat input ports and plurality of thermostat output ports to the HVAC / R system when in a second mode.

[0022] In one aspect of the disclosure, the ECU is configured to receive a diagnostic request for the HVAC / R system and control the HVAC / R system based on the diagnostic request through the switching assembly when the switching assembly is in the second mode.

[0023] In one aspect of the disclosure, the ECU is configured to control operation of the HVAC / R system independently of the electrical communications from the thermostat to perform the diagnosis request when the switching assembly is in the second mode.

[0024] Disclosed herein is a non-transitory computer-readable storage medium embodying programmed instructions which, when executed by a processor, are operable for performing a method of operating an HVAC / R system. The method includes receiving a request for sensor data from VO ports regarding operation of an HVAC / R system with the VO ports including at least one of current sensing ports, temperature sensing ports, or thermostat voltage ports that are each fixed relative to a housing. The method also includes controlling a sensor in communication with at least one of the I / O ports based on the request for sensor data, collecting sensor data from the sensor in communication with the at least one of the VO ports, and transmitting the sensor data to a remote location.

[0025] In one aspect of the disclosure, the method includes controlling an operational state of an HVAC / R system and the plurality of thermostat voltage ports includes a plurality of thermostat input ports configured to receive electrical communications from a thermostat and a plurality of thermostat output ports configured to transmit the electrical communications from the thermostat to the HVAC / R system.

[0026] In one aspect of the disclosure, the method includes controlling a switching assembly configured to transfer the electrical communications from the thermostat at the plurality of thermostat input ports to the HVAC / R system through the plurality of thermostat output ports when in a first mode and separate the electrical communications from thethermostat to the plurality of thermostat input ports and plurality of thermostat output ports to the HVAC / R system when in a second mode.

[0027] In one aspect of the disclosure, the method includes receiving a diagnostic request for the HVAC / R system and controlling the HVAC / R system based on the diagnostic request through the switching assembly when the switching assembly is in the second mode.

[0028] Disclosed herein is a method of operating a monitoring device for an HVAC / R system. The method includes receiving a request for sensor data from I / O ports regarding operation of an HVAC / R system with the I / O ports including at least one of current sensing ports, temperature sensing ports, or thermostat voltage ports that are each fixed relative to a housing. The method also includes controlling a sensor in communication with at least one of the I / O ports based on the request for sensor data, collecting sensor data from the sensor in communication with the at least one of the I / O ports, and transmitting the sensor data to a remote location.

[0029] In one aspect of the disclosure, the method includes controlling an operational state of an HVAC / R system and the plurality of thermostat voltage ports includes a plurality of thermostat input ports configured to receive electrical communications from a thermostat and a plurality of thermostat output ports configured to transmit the electrical communications from the thermostat to the HVAC / R system.

[0030] In one aspect of the disclosure, the method includes controlling a switching assembly configured to transfer the electrical communications from the thermostat at the plurality of thermostat input ports to the HVAC / R system through the plurality of thermostat output ports when in a first mode and electrically isolate the electrical communications from the thermostat to the plurality of thermostat input ports and plurality of thermostat output ports to the HVAC / R system when in a second mode.

[0031] In one aspect of the disclosure, the method includes receiving a diagnostic request for the HVAC / R system and controlling the HVAC / R system based on the diagnostic request through the switching assembly when the switching assembly is in the second mode.DETAILED DESCRIPTION

[0032] The present disclosure is susceptible of embodiment in many different forms. Representative examples of the disclosure are shown in the drawings and described herein in detail as non-limiting examples of the disclosed principles. To that end, elements and limitations described in the Abstract, Introduction, Summary, and Detailed Descriptionsections, but not explicitly outlined in the claims, should not be incorporated into the claims, singly or collectively, by implication, inference, or otherwise.

[0033] As the demand for improved HVAC / R system efficiency increases, HVAC / R systems have become increasingly complex pieces of equipment that are heavily relied upon by individuals and businesses. Original equipment manufacturers (“OEMs”) of HVAC / R systems have developed control systems that direct the operation of the HVAC / R system. These control systems rely on input from multiple sensors integrated into the HVAC / R system to provide enhanced climate control capabilities. Furthermore, because OEMs have created the control systems for HVAC / R systems, they can collect data from sensors incorporated directly into the system to ensure it is operating correctly. However, OEM monitoring systems are generally only available directly through the OEM due to the proprietary nature of their systems. One feature of this disclosure is to provide a robust monitoring system without the need to communicate with sensors or electronics in the OEM HVAC / R system.

[0034] FIG. 1 illustrates a monitoring device 20 used to monitor a device, such as an HVAC / R system 22 (FIG. 3). In this disclosure, the terms device and system may be used interchangeably due to the applicability of the monitoring device to a single component in the HVAC / R system or the entire HVAC / R system itself. As shown, the monitoring device 20 is a standalone device that operates independently of the HVAC / R device 22 and includes multiple input / output (“IO”) ports that allow for receiving and transmitting sensor data regarding parameters and characteristics of the HVAC / R system 22 and its surrounding environment. One feature of this disclosure is that the monitoring device 20 obtains information regarding the HVAC / R system 22 separately from sensors that are integrated into the HVAC / R system 22 by the OEM. This allows the monitoring device 20 to operate without requiring access to proprietary components of the HVAC / R system 22.

[0035] As shown in FIGS. 1-2, the monitoring device 20 includes a housing 24 that at least partially encloses an internal cavity including circuitry for operating the monitoring device 20. In the illustrated example, various types of input / output (I / O) ports are accessible through corresponding openings in the housing 24, which interface with sensors or allow for communicating data to or from the monitoring device 20. In one example, the VO ports are fixed relative to the housing and can include 3.5 mm jack ports, clamps, coaxial ports, or various types of USB ports.

[0036] In the illustrated example, a user can activate the monitoring device 20 with a power switch 26 and receive visible feedback regarding the operation of the monitoring device 20 from a series of indicator lights 28. The indicator lights 28 can include light-emitting diodes(LEDs) that selectively operate between steady illumination, blinking illumination, or different colors to visually communicate to the user an operating status of the monitoring device 20. For example, the operating status can identify faulty sensors, select various operating modes including data collection rates, identify a network connectivity status, etc. A user can also form a direct communication connection with the monitoring device 20 through a data transfer port 30, such as a USB port, to allow bi-directional transfer of data with the monitoring device 20. This allows the user to provide further updates or customized operating modes for the monitoring device 20.

[0037] In one example, the monitoring device 20 collects sensor data from sensors forming a direct electrical connection with one of the I / O ports integrated therein. In the illustrated example, there are two different types of sensor I / O ports on the monitoring device 20. However, two or more types of I / O ports can be incorporated into the monitoring device 20, depending on the type of sensors interfacing with the monitoring device 20. As shown in FIG. 1, a first set of I / O ports 32-1 through 32-8 includes eight separate I / O ports, and a second set of I / O ports 34 includes another eight separate I / O ports. The specific types of sensors and data that they collect will be discussed in greater detail below. Data collected by the monitoring device 20 can be transferred through the data transfer port 30 or wirelessly to a remote location 40 through an antenna 36 connected to a wireless communications port 38, such as a coaxial cable port. In one example, the antenna 36 is configured to communicate over a cellular network.

[0038] As shown in FIG. 2, the monitoring device 20 includes an electronic control unit (ECU) 42 connected to a printed circuit board (“PCB”) 43. Although the ECU 42 shown in FIG. 2 is depicted as a box for illustrative clarity and simplicity, the ECU 42 within the scope of the disclosure could include one or more networked devices each with a central processing unit or other processor (P) 44 and sufficient amounts of memory (M) 46, including a non- transitory (e.g., tangible) medium that participates in providing data / instructions that may be read by the processor(s) 44. Instructions embodying a method 200 described below may be stored in the memory 46 and executed by the processor 44 to perform the various functions described herein, thus enabling the present method 200 described below and exemplified in FIG. 7.

[0039] The memory 46 may take many forms, including but not limited to non-volatile media and volatile media. Non-volatile media may include optical and / or magnetic disks or other persistent memory. In contrast, volatile media may include dynamic random-accessmemory (DRAM), static RAM (SRAM), etc., any or all of which may constitute a main memory of the ECU 42.

[0040] Other hardware not depicted but commonly used in the art may be included as part of the ECU 42, including but not limited to a local oscillator or high-speed clock, signal buffers, filters, etc. The ECU 42 of FIG. 2 may be configured to communicate via a network (not shown), for instance a serial bus, a local area network, a controller area network, a controller area network with flexible data rate, or via Ethernet, Wi-Fi, Bluetooth™, LoRaWAN, near- field communication, and / or other forms of wired or wireless data connection, such as a satellite connection.

[0041] The ECU 42 is in electrical communication with the power switch 26, the indicator lights 28, the data transfer port 30, the first and second sets of ports 32 and 34, and the wireless communications port 38 through electrical circuitry on a printed circuit board (PCB) 43. A power port 48 is in electrical communication with ECU 42 and a power source 49 to allow the ECU 42 to control power distribution through the monitoring device 20. The power source 49 can include a battery power source or a grid-tied power source. A capacitor 50 may also supplement power to the ECU 42 to address fluctuations in power to the monitoring device 20.

[0042] FIG. 3 illustrates one example HVAC / R system 22 with the monitoring device 20 monitoring operation of the HVAC / R system 22. However, other styles of HVAC / R systems, such as package units, air handlers, gas or electric heaters, heat pumps, split or mini-split units, water cooling towers, and refrigeration units (ammonia or refrigerant-based), can also benefit from the monitoring devices of this disclosure. As shown in FIG. 3, the example HVAC / R system 22 includes a housing 60 that receives air to be conditioned from an air inlet duct 62. The air inlet duct 62 directs air through a heat exchanger 64 due to a pressure differential generated by a blower motor 66. The heat exchanger 64 can include a fluid inlet 641, a fluid outlet 640, and a water inlet 64W for a humidifier integrated into the heat exchanger 64. Alternatively, the humidifier could be a separate unit from the heat exchanger 64.

[0043] The operation of the blower motor 66 and the HVAC / R system 22 is managed by a controller 70 integrated into the HVAC / R system 22 that interfaces with a thermostat 72. The blower motor 66 draws the air past the heat exchanger 64 into an air outlet duct 68 that leads back to a conditioned space (not shown).

[0044] As shown in FIGS. 1 and 3, multiple different sensors are located throughout the HVAC / R system 22, with information collected from the sensors by the monitoring device 20. The first set of I / O ports 32 includes eight separate ports. In the illustrated example, a subset of these ports is directed to collect power-related information through corresponding currentclamps, such that these ports operate as current measuring or sensing ports. In the illustrated example, a first port 32-1 is in electrical communication with a first current clamp Ci, a second port 32-2 is in electrical communication with a second current clamp C2, a third port 32-3 is in electrical communication with a third current clamp C3, and a fourth port 32-4 is in electrical communication with a fourth clamp C4.

[0045] As shown in FIG. 3, the first, second, and third current clamps Ci, C2, and C3 each surround a phase Pi, P2, and P3, respectively, of a three-phase power line 51 to the HVAC / R system 22, while the fourth current clamp C4 surrounds a blower motor power line. The current clamps Ci, C2, and C3 allow the monitoring device 20 to observe and record power consumption for the HVAC / R system 22 through the three-phase power line 51. In contrast, the fourth current clamp C4 enables the monitoring device 20 to monitor the power consumption and operating status of the blower motor 66. Monitoring these power lines enables the monitoring device 20 to identify changes in power consumption by comparing them to historical data, as well as determine whether the HVAC / R system 22 or the blower motor 66 is receiving power as part of a troubleshooting analysis performed by the monitoring device 20. While the illustrated example provides possible locations for the current clamps that communicate with the monitoring device 20, a varying number of current clamps could be used based on the specific application, such as if the HVAC / R system 22 included multiple blower motors 66.

[0046] Another set of the I / O ports 32 includes a subset of temperature-measuring-related ports that are directed to collect temperature-related information from corresponding temperature sensors, such as thermocouples, throughout the HVAC / R system 22. In the illustrated example, a fifth port 32-5 is in electrical communication with an inlet temperature sensor Ti, a sixth port 32-6 is in electrical communication with an outlet temperature sensor To, a seventh port 32-7 is in electrical communication with an ambient temperature sensor TA, and an eighth port 32-8 is in electrical communication with an exterior temperature sensor TE. Alternatively, the ports 32-5 through 32-8 could be used for other types of single-wire connections, such as for additional temperature readings.

[0047] The inlet temperature sensor Ti is located in the air inlet duct 62 and measures the temperature of the air from the conditioned space as it enters the HVAC / R system 22. The outlet temperature sensor To is located in the air outlet duct 68 and measures the temperature of the air leaving the HVAC / R system 22 and returning to the conditioned space. The ambient temperature sensor TA is located within an enclosure of the HVAC / R system 22 or adjacent to the HVAC / R system 22 for measuring the temperature of the ambient air around the HVAC / Rsystem 22. The exterior temperature sensor TE is located in an outdoor environment and measures the outdoor or exterior temperature of the environment surrounding the space conditioned by the HVAC / R system 22. While the illustrated example provides possible locations for the temperature sensors that communicate with the monitoring device 20, a varying number of temperature sensors could be used based on the specific application, such as if the HVAC / R system 22 included multiple air inlet ducts 62 or air outlet ducts 68, or if the space contains multiple zones for conditioning.

[0048] In the illustrated example, the second set of I / O ports 34 includes seven I / O ports that monitor commands from the thermostat 72, however, a different number of I / O ports 34 could be utilized depending on the thermostat 72. In the illustrated example, a first port 34-1 is in electrical communication with a voltage sensor Vy configured to measure a voltage in a cooling command line 72-Y from the thermostat 72 to the HVAC / R system 22. The monitoring device 20 can use the voltage sensor Vy to determine if the thermostat 72 has provided instructions to the HVAC / R system 22 to begin cooling by monitoring the voltage in the cooling command line 72-Y. This allows the monitoring device 20 to identify the operational state of the HVAC / R system 22 to determine if the thermostat 72 is providing the desired instructions to the HVAC / R system 22 or if there is a fault with the thermostat 72 when the HVAC / R system 22 does not provide cooling. In one example, determining if the HVAC / R system 22 is supplying cooling is provided by measuring a temperature differential between the inlet temperature sensor Ti and the outlet temperature sensor To and comparing the differential to a predetermined threshold value.

[0049] Similarly, a second port 34-2 is in electrical communication with a voltage sensor Vw, configured to measure a voltage in a heating command line 72-W from the thermostat 72 to the HVAC / R system 22. While the illustrated example includes both a heating command line 72-W and a cooling command line 72-Y, the HVAC / R system 22 may provide just heating or cooling and not require both command lines. The monitoring device 20 can use the voltage sensor Vw to determine if the thermostat 72 has provided instructions to the HVAC / R system 22 to begin heating by monitoring the voltage in the heating command line 72-W. This allows the monitoring device 20 to identify the operational state of the HVAC / R system 22 to determine if the thermostat 72 is instructing the HVAC / R system 22 to produce heat or if there is a fault with the thermostat 72 when the monitoring device 20 determines that the HVAC / R system 22 does not provide heat. In one example, determining if the HVAC / R system 22 is supplying heat is provided by measuring the temperature differential between the inlettemperature sensor Ti and the outlet temperature sensor To and comparing the differential to a predetermined threshold value.

[0050] A third port 34-3 is in electrical communication with a voltage sensor VG, configured to measure a voltage in a blower command line 72-G from the thermostat 72 to the HVAC / R system 22. The monitoring device 20 can use the voltage sensor VG to determine if the thermostat 72 has provided instructions to the HVAC / R system 22 to turn on the blower motor 66 by monitoring a voltage in the blower command line 72-G. This allows the monitoring device 20 to identify the operational state of the HVAC / R system 22. It determines if the thermostat 72 is instructing the HVAC / R system 22 or if there is a fault with the thermostat 72, in the event the blower motor 66 is not operating when instructed by the thermostat 72.

[0051] A fourth port 34-4 and a fifth port 34-5 are in electrical communication with a voltage sensor VRCand a voltage sensor VRI,, respectively, for measuring a power supply to the HVAC / R system 22, such as a 24V power supply, in a voltage command line 72-VRCand a voltage command line 72-VRH. The voltage sensor VRCmeasures the power supply for operating cooling contactors through the voltage command line VRC, and the voltage sensor VRI, measures the power supply for operating heating contactors through the voltage command line VRI,. The monitoring device 20 can use the voltage sensors VRCand VRI, to determine if the thermostat 72 is receiving the necessary power to activate the cooling or heating functions, respectively, for the HVAC / R system 22. This information can be further used to identify a fault in the HVAC / R system 22 if the voltage readings from the sensors VRCor VRI, are outside of predetermined threshold values.

[0052] A sixth port 34-6 and a seventh portion 34-7 are in electrical communication with a ground voltage sensor V. and a positive voltage sensor V+, respectively, through a ground line 72-N and a power line 72-P. The voltage sensor V. determines if the thermostat 72 has a proper ground, and the voltage sensor V+ determines if the voltage of the power source, such as a 24V power source, to thermostat 72 is within a predetermined range of values.

[0053] While the above examples illustrate various sensors in direct electrical communication with the monitoring device 20 through one of its multiple ports 32 or 34, the monitoring device 20 can communicate wirelessly with a wireless sensor 80 (FIG. 1) through a wireless chip 82 (FIG. 2) or the antenna 36 (FIG. 1). Additional types of sensors that could include either wired or wireless connections include fluid sensors for determining leaks in the HVAC / R system 22 or gas sensors for determining a leak of refrigerant from the heat exchanger 64. Depending on the sample frequency for the sensor 80, the wireless chip 82 may include a long-range wide-area network (LoRaWan) chip. This will allow the sensor 80 to be battery-operated and have a long operating life span, such as months or years, eliminating the need for frequent battery service.

[0054] Furthermore, the monitoring device 20 could include a microphone 84 located within or adjacent to the housing 24 and in electrical communication with the ECU 42 for monitoring noise levels in the area surrounding the monitoring device 20. In particular, the microphone 84 can identify changes in noise levels by comparing a current noise level to a historical noise level for a corresponding operation of the HVAC / R system 22. Alternatively, the microphone 84 can identify predetermined frequency ranges that might indicate a component, such as a bearing, in the HVAC / R system 22, that may need servicing before failure of that component.

[0055] FIGS. 4-6 illustrate another example of a monitoring device 120. The monitoring device 120 is similar to the monitoring device 20 except where described below or shown in the drawings. Similar or like components will include the addition of a leading “1” to the reference numerals from the monitoring device 20. The monitoring device 120 includes a housing 124 that at least partially encloses an internal cavity or volume that includes circuitry for the operation of the monitoring device 120. In the illustrated example, various types of VO ports are accessible through corresponding openings in the housing 124 that interface with sensors or allow for communicating data to or from the monitoring device 20.

[0056] In the illustrated example, a user can activate the monitoring device 120 with a power switch 126 and receive visible feedback regarding the operation of the monitoring device 120 from a series of indicator lights 128. A user can also form a direct communication connection with the monitoring device 120 through a data transfer port 130, such as a USB port, to allow bi-directional transfer of data with the monitoring device 120. This allows the user to provide further updates or customized operating modes for the monitoring device 120.

[0057] In one example, the monitoring device 120 collects sensor data through a direct electrical connection with one of the I / O ports integrated therein. In the illustrated example, there are two different types of sensor I / O ports on the monitoring device 120. However, two or more kinds of VO ports can be incorporated into the monitoring device 120, depending on the type of sensors interfacing with the monitoring device 120. As shown in FIG. 1, a first set of I / O ports 132-lthrough 132-8 includes eight separate VO ports, a second set of I / O ports 134 includes eight separate VO ports, and a third set of I / O ports 135 includes eight separate I / O ports. The specific types of sensors and data that they collect will be discussed in greater detail below. Data collected by the monitoring device 120 can be transferred through the data transfer port 130 or wirelessly to the remote location 40 through an antenna 136 connected to a wirelesscommunications port 138, such as a coaxial cable port. In one example, the antenna 136 is configured to communicate over a cellular network.

[0058] The monitoring device 120 includes an electronic control unit (ECU) 142 connected to a PCB 143. Although the ECU 142 shown in FIG. 6 is depicted as a box for illustrative clarity and simplicity, the ECU 142 within the scope of the disclosure could include one or more networked devices each with a central processing unit or other processor (P) 144 and sufficient amounts of memory (M) 146, including a non-transitory (e.g., tangible) medium that participates in providing data / instructions that may be read by the processor(s) 144. Instructions embodying a method 200 described below may be stored in the memory 146 and executed by the processor 144 to perform the various functions described herein, thus enabling the present method 200 described below and exemplified in FIG. 7.

[0059] The ECU 142 is in electrical communication with the power switch 126, the indicator lights 128, the data transfer port 130, the first, second, and third sets of ports 132, 134, 135, and the wireless communications port 138 through electrical circuitry on a printed circuit board (PCB) 143. A power port 148 is in electrical communication with ECU 142 and the power source 49 to allow the ECU 142 to control power distribution through the monitoring device 120. A capacitor 150 may also supplement power to the ECU 142 to address fluctuations in power to the monitoring device 120.

[0060] As shown in FIG. 6, the first, second, and third current clamps Ci, C2, and C3 each surround a phase Pi, P2, and P3, respectively, of a three-phase power line 51 to the HVAC / R system 22, while the fourth current clamp C4 surrounds a blower motor power line. The current clamps Ci, C2, and C3 allow the monitoring device 120 to observe and record power consumption for the HVAC / R system 22 through the three-phase power line 51. In contrast, the fourth current clamp C4 allows the monitoring device 120 to monitor the power consumption and operating status of the blower motor 66.

[0061] Another set of the VO ports 132 includes a subset of temperature-measuring-related ports that are directed to collect temperature-related information from corresponding temperature sensors, such as thermocouples, throughout the HVAC / R system 22. In the illustrated example, a fifth port 132-5 is in electrical communication with the inlet temperature sensor Ti, a sixth port 132-6 is in electrical communication with the outlet temperature sensor To, a seventh port 132-7 is in electrical communication with the ambient temperature sensor TA, and an eighth port 132-8 is in electrical communication with the exterior temperature sensor TE. Alternatively, the ports 132-5 through 132-8 could be used for other types of single-wire connections, such as for additional temperature readings.

[0062] In the illustrated example, the second set of I / O ports 134 includes seven I / O ports that receive commands from the thermostat 72 that pass through a sensor and switching assembly 137 to corresponding ports on the third set of I / O ports 135. In one example, the ports 134 are thermostat input ports and the ports 135 are thermostat output ports. In the illustrated example, the cooling command line 72-Yl from the thermostat 72 is in electrical communication with a first port 134-1 of the second set of I / O ports 134. A first port 135-1 of the third set of I / O ports 135 selectively connects the cooling command line 72-Yl to a cooling command line 172-Yl that is in electrical communication with the controller 70 utilizing the assembly 137. This allows the voltage in the cooling command line 72-Y 1 to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the cooling command line 172-Yl without interfacing with the thermostat 72 by isolating the cooling command line 72- Y1 from the cooling command line 172-Yl.

[0063] The heating command line 72-W1 from the thermostat 72 is in electrical communication with a second port 134-2 of the second set of VO ports 134. The second port 135-2 of the third set of VO ports 135 selectively connects the heating command line 72-W1 to a heating command line 172-W1 that is in electrical communication with the controller 70 through the assembly 137. This allows the voltage in the heating command line 72-W1 to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the heating command line 172-W1 without interfacing with the thermostat 72 by electrically by isolating the heating command line 72-W1 from the heating command line 172-W1.

[0064] The blower command line 72-G from the thermostat 72 is in electrical communication with a third port 134-3 of the second set of I / O ports 134. A third port 135-3 of the third set of I / O ports 135 selectively connects the blower command line 72-G to a blower command line 172-G that is in electrical communication with the controller 70 utilizing the assembly 137. This allows the voltage in the blower command line 72-G to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the blower command line 172-G without interfacing with the thermostat 72 by isolating the blower command line 72-G from the blower command line 172-G.

[0065] The command line 72-Y2 (Second Stage Cooling) from the thermostat 72 is in electrical communication with a fourth port 134-4 of the second set of VO ports 134. A fourth port 135-4 of the third set of VO ports 135 selectively connects the command line 72-Y2 to acommand line 172-Y2 that is in electrical communication with the controller 70 utilizing the assembly 137. This allows the voltage in the command line 72-Y2 to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the command line 172-Y2 without interfacing with the thermostat 72 by isolating the command line 72-Y2 from the command line 172-Y2.

[0066] The command line 72-W2 (Second Stage Heating) from the thermostat 72 is in electrical communication with a fifth port 134-5 of the second set of I / O ports 134. A fifth port 135-5 of the third set of I / O ports 135 selectively connects the command line 72-W2 to a command line 172-W2 that is in electrical communication with the controller 70 utilizing the assembly 137. This allows the voltage in the command line 72-W2 to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the command line 172-W2 without interfacing with the thermostat 72 by isolating the command line 72-W2 from the command line 172-W2.

[0067] The command line 72-N (Ground) from the thermostat 72 is in electrical communication with a sixth port 134-6 of the second set of I / O ports 134. A sixth port 135-6 of the third set of VO ports 135 selectively connects the command line 72-N to a command line 172-N that is in electrical communication with the controller 70 through the assembly 137. This allows the voltage in the command line 72-N to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the command line 172-N without interfacing with the thermostat 72 by isolating the command line 72-N from the cooling command line 172-N.

[0068] The command line 72-P (Power) from the thermostat 72 is in electrical communication with a seventh port 134-7 of the second set of I / O ports 134. A seventh port 135-7 of the third set of VO ports 135 selectively connects the command line 72-P to a command line 172-P that is in electrical communication with the controller 70 utilizing the assembly 137. This allows the voltage in the command line 72-P to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the command line 172-P without interfacing with the thermostat 72 by isolating the command line 72-P from the cooling command line 172-P.

[0069] The command line 72-0 (Heat Pump Reversing Valve) from the thermostat 72 is in electrical communication with an eighth port 134-8 of the second set of I / O ports 134. An eighth port 135-8 of the third set of I / O ports 135 selectively connects the command line 72-0 to a command line 172-0 that is in electrical communication with the controller 70 utilizing the assembly 137. This allows the voltage in the command line 72-0 to be monitored by the assembly 137. Additionally, the assembly 137 allows the ECU 142 to selectively send a testing or diagnostic signal in response to a diagnosis request through the command line 172-0 without interfacing with the thermostat 72 by isolating the command line 72-0 from the cooling command line 172-0.

[0070] However, the above second and third sets of ports, 134 and 135, can connect with different command lines depending on the HVAC / R system 22 and the commands used for operation from the thermostat 72.

[0071] While the above examples illustrate various sensors in direct electrical communication with the monitoring device 120 through one of its multiple ports 132, the monitoring device 120 can communicate wirelessly with a wireless sensor 80 (FIG. 1) through a wireless chip 182 (FIG. 5) or the antenna 136 (FIG. 4) as discussed above with respect to the monitoring device 20. Furthermore, the monitoring device 120 could include a microphone 184 located within or adjacent to the housing 124 and in electrical communication with the ECU 142 for monitoring noise levels in the area surrounding the monitoring device 120 as discussed above with respect to the monitoring device 20.

[0072] FIG. 7 illustrates an example method 200 of operating one of the monitoring devices 20, 120. The method 200 begins at block 202 (“Receive request for sensor data”) by receiving a request for sensor data from the remote location. In one example, the request for sensor data can correspond to a component on the HVAC / R system 22 for testing, such as heating, cooling, or air circulation. With the request for sensor data, the method 200 then proceeds to block 204.

[0073] At block 204 (“Control sensor(s)”), the method 200 activates one of the sensors, such as one or more of the assembly 137, current sensors, temperature sensors, or other sensors as described above, depending on the type of device and parameters being monitored. For example, the request for sensor data can include a request for ambient temperature as well as temperatures at the inlet and outlet of the HVAC / R system 22. With the sensor(s) being controlled, the method 200 then proceeds to block 206.

[0074] At block 206 (“Collect sensor data”), the method 200 collects sensor data based on the request for sensor data from the sensors that correspond to the request. In one example, a user can then control the thermostat 72 through various settings, such as heating modes, coolingmodes, or fan modes, to analyze how the HVAC / R system 22 is performing. Furthermore, while the method 200 is collecting sensor data at block 206, the method 200 can receive a diagnostic request. In one example, for the monitoring device 120, the diagnostic request can include a series of operations for the HVAC / R system 22 to perform while the sensor data is being collected. These operations are controlled by utilizing the assembly 137 independently of the thermostat 72 as described above with respect to the ECU 142 and the assembly 137. With the sensor data collected, the method 200 then proceeds to block 208.

[0075] At block 208 (“Transmit sensor data”), the sensor data that was collected at block 206 is transferred or transmitted to the remote location 40. The data can be transferred wirelessly, such as through a Wi-Fi or cellular connection, or through the data transfer port 30, 130. The sensor data can be analyzed directly on the monitoring device 20, 120 by the ECU 42, 142, respectively, or the sensor data can be analyzed at the remote location 40. For the example of the monitoring device 120, the monitoring device 120 can control operation of the HVAC / R system 22 through the command lines 172 if it is determined that the thermostat 72 is faulty and in need of repair. This allows the HVAC / R system 22 to remain in operation until the thermostat 72 can be repaired.

[0076] In another example, the collected data may be organized at the remote location 40 through a dashboard arrangement on a webpage on a display 41 made accessible through the internet. Additionally, the dashboard can display current operating parameters for the HVAC / R system 22 with a comparison to historical operating parameters to help identify potentially failure points in the HVAC / R system 22 before a conditioning performance of the HVAC / R system 22 degrades to a point where the conditioned space is no longer comfortable, such as including a temperature or humidity outside of predetermined ranges. The dashboard or the analysis of the data collected can also perform various troubleshooting procedures by identifying inconsistencies in operation, such as an instruction from the thermostat for cooling with a temperature differential between the air inlet duct 62 and the air outlet duct 68 outside of a predetermined range.

[0077] One feature of this disclosure, as described above, is that the monitoring devices 20, 120 monitor operating parameters or characteristics of the HVAC / R system 22 independently of the sensors integrated into the HVAC / R system 22 by the OEM and without the ability to control or change an operating state of the HVAC / R system 22 itself.

[0078] The terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The term “or” means “and / or” unless clearly indicated otherwise by context. Reference throughout the specification to “an aspect” meansthat a particular element (e.g., feature, structure, step, or characteristic) described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it is to be understood that the described elements may be combined suitably in the various aspects.

[0079] While the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from its scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed but will include embodiments falling within the scope thereof.

Claims

CLAIMSWhat is claimed is:

1. A monitoring device for a heating, ventilation, air conditioning, and refrigeration (HVAC / R) system, comprising: a housing enclosing an internal cavity; a plurality of input / output (I / O) ports fixed relative to the housing, wherein the plurality of I / O ports includes a plurality of current sensing ports, a plurality of temperature sensing ports, and a plurality of thermostat voltage ports; and an electronic control unit (ECU) located within the housing and in electrical communication with the plurality of I / O ports, wherein the ECU is configured to: receive a request for sensor data regarding operation of the HVAC / R system from at least one of the plurality of current sensing ports, the plurality of temperature sensing ports, or the plurality of thermostat voltage ports; control a sensor in communication with one of the plurality of I / O ports based on the request for sensor data; collect sensor data from the sensor in communication with the one of the plurality of VO ports; and transmit the sensor data to a remote location.

2. The monitoring device of claim 1, including a temperature sensor in electrical communication with the ECU through each of the plurality of temperature sensing ports.

3. The monitoring device of claim 1, including a thermostat voltage sensor in electrical communication with the ECU through each of the plurality of thermostat voltage ports.

4. The monitoring device of claim 1, including a current clamp in electrical communication with the ECU through each of the plurality of current sensing ports.

5. The monitoring device of claim 4, wherein the current clamp includes a blower current clamp configured to determine an operational state of a blower on the HVAC / R system.

6. The monitoring device of claim 1, wherein the plurality of I / O ports includes a communications port.

7. The monitoring device of claim 6, including an antenna in electrical communication with the ECU through the communications port and the antenna is configured to transmit the sensor data collected by the ECU to the remote location.

8. The monitoring device of claim 1, wherein the ECU is configured to control an operational state of the HVAC / R system.

9. The monitoring device of claim 8, wherein the plurality of thermostat voltage ports includes a plurality of thermostat input ports configured to receive electrical communications from a thermostat and a plurality of thermostat output ports configured to transmit the electrical communications from the thermostat to the HVAC / R system.

10. The monitoring device of claim 9, wherein the ECU is configured to control a switching assembly and the switching assembly is configured to transfer the electrical communications from the thermostat at the plurality of thermostat input ports to the HVAC / R system through the plurality of thermostat output ports when in a first mode and electrically isolate the electrical communications from the thermostat to the plurality of thermostat input ports and plurality of thermostat output ports to the HVAC / R system when in a second mode.

11. The monitoring device of claim 10, wherein the ECU is configured to receive a diagnostic request for the HVAC / R system and control the HVAC / R system based on the diagnostic request through the switching assembly when the switching assembly is in the second mode.

12. The monitoring device of claim 11, wherein the ECU is configured to control operation of the HVAC / R system independently of the electrical communications from the thermostat to perform the diagnosis request when the switching assembly is in the second mode.

13. A non-transitory computer-readable storage medium embodying programmed instructions which, when executed by a processor, are operable for performing a method of operating a heating, ventilation, air conditioning, and refrigeration (HVAC / R) system, the method comprising: receiving a request for sensor data from a plurality of input / output (VO) ports regarding operation of the HVAC / R system, wherein the plurality of VO ports includeat least one of a plurality of current sensing ports, a plurality of temperature sensing ports, or a plurality of thermostat voltage ports, and wherein the plurality of I / O ports are fixed relative to a housing; controlling a sensor in communication with at least one of the plurality of I / O ports based on the request for sensor data; collecting sensor data from the sensor in communication with the at least one of the plurality of I / O ports; and transmitting the sensor data to a remote location.

14. The computer-readable storage medium of claim 13, wherein the method includes controlling an operational state of the HVAC / R system and the plurality of thermostat voltage ports includes a plurality of thermostat input ports configured to receive electrical communications from a thermostat and a plurality of thermostat output ports configured to transmit the electrical communications from the thermostat to the HVAC / R system.

15. The computer-readable storage medium of claim 14, wherein the method includes controlling a switching assembly configured to transfer the electrical communications from the thermostat at the plurality of thermostat input ports to the HVAC / R system through the plurality of thermostat output ports when in a first mode and separate the electrical communications from the thermostat to the plurality of thermostat input ports and plurality of thermostat output ports to the HVAC / R system when in a second mode.

16. The computer-readable storage medium of claim 15, wherein the method includes receiving a diagnostic request for the HVAC / R system and controlling the HVAC / R system based on the diagnostic request through the switching assembly when the switching assembly is in the second mode.

17. A method of operating a monitoring device for a heating, ventilation, air conditioning, and refrigeration (HVAC / R) system, the method comprising: receiving a request for sensor data from a plurality of input / output (I / O) ports regarding operation of the HVAC / R system, wherein the plurality of I / O ports includes at least one of a plurality of current sensing ports, a plurality of temperature sensing ports, or a plurality of thermostat voltage ports and the plurality of I / O ports are fixed relative to a housing;controlling a sensor in communication with at least one of the plurality of I / O ports based on the request for sensor data; collecting sensor data from the sensor in communication with the at least one of the plurality of I / O ports; and transmitting the sensor data to a remote location.

18. The method of claim 17, wherein the method includes controlling an operational state of the HVAC / R system and the plurality of thermostat voltage ports includes a plurality of thermostat input ports configured to receive electrical communications from a thermostat and a plurality of thermostat output ports configured to transmit the electrical communications from the thermostat to the HVAC / R system.

19. The method of claim 18, wherein the method includes controlling a switching assembly configured to transfer the electrical communications from the thermostat at the plurality of thermostat input ports to the HVAC / R system through the plurality of thermostat output ports when in a first mode and electrically isolate the electrical communications from the thermostat to the plurality of thermostat input ports and plurality of thermostat output ports to the HVAC / R system when in a second mode.

20. The method of claim 19, wherein the method includes receiving a diagnostic request for the HVAC / R system and controlling the HVAC / R system based on the diagnostic request through the switching assembly when the switching assembly is in the second mode.

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