Connection box for condensate pumps in air-conditioning units
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Solution Overview
Problem
Existing air-conditioning systems face challenges in efficiently managing condensate overflow, particularly in commercial settings, where manual emptying is impractical, and condensate pumps may malfunction, leading to system shutdowns or water damage, while integration with building management systems requires complex re-wiring and technical knowledge.
Innovation Solution
A connection box with clearly labeled terminal blocks and a relay circuit that simplifies the installation of condensate pumps by allowing external connections to a condensate pump and AC unit, enabling safe operation and integration with or without a building management system, using a normally closed or open configuration to manage high water levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a condensate pump is used to empty the reservoir, then the reservoir can be smaller and the AC unit more appealing, but the pump may malfunction and cause water damage
Solution Approach 1:
The system is segmented into distinct functional components: the reservoir, the condensate pump, the connection box with relay circuit, and the control system. This segmentation allows the reservoir to be smaller while maintaining safety through independent monitoring and control mechanisms.
Solution Approach 2:
The relay circuit is configured to cut off power to the evaporator before water damage can occur. The high water level switch and relay circuit prepare the system in advance by establishing automatic shutdown capability, so that when the pump malfunctions, the power is already cut off or can be quickly cut off to prevent damage.
2Object-affected harmful factors
If a water level switch is fitted to the condensate pump, then overflow risk is reduced, but the system becomes less reliable due to moving parts in the pump
Solution Approach 1:
The relay circuit acts as an intermediary between the water level switch and the evaporator power supply. The relay contains the moving parts (switching mechanism) separate from the pump, allowing the pump to remain simple and reliable while still providing overflow protection through the relay's switching action.
Solution Approach 2:
The system replaces direct mechanical coupling between the water level switch and pump control with an electromagnetic relay system. This substitution allows the water level detection to control power delivery through the relay circuit, reducing mechanical complexity in the pump itself while maintaining protection capability.
3Object-affected harmful factors
If the AC unit is shut down on high water level alert, then water damage is prevented, but the AC unit cannot operate in scenarios where overflow risk is acceptable
Solution Approach 1:
The relay circuit is designed to be reconfigurable between normally closed and normally open states, allowing the system to dynamically adapt its shutdown behavior. This enables the same hardware to serve both safety-critical applications (where shutdown is required) and flexible applications (where continuous operation is preferred).
Solution Approach 2:
The system allows changing the operational parameter of the relay (normally closed vs. normally open state) to adapt to different application requirements. This parameter change enables the system to switch between safety-first operation and flexibility-first operation without hardware modification.
4Extent of automation
If the AC unit and condensate pump are integrated into a BMS, then centralized control is achieved, but complex re-wiring is required
Solution Approach 1:
The complex wiring and control logic are extracted from the AC unit and condensate pump themselves and consolidated into a separate connection box. This externalization of complexity allows the main AC unit and pump to remain simple devices that can be easily integrated into a BMS without requiring internal modifications or complex re-wiring.
Solution Approach 2:
The connection box serves as an intermediary device between the AC unit, condensate pump, and BMS. It provides standardized connection terminals and handles the complex control logic, allowing straightforward integration with BMS while shielding the AC unit and pump from wiring complexity.
5Extent of automation
If installers re-wire the electronics to integrate with BMS, then centralized management is enabled, but installation time and technical knowledge requirements increase
Solution Approach 1:
The BMS integration functionality is extracted into a separate connection box with pre-configured terminals and circuitry. This allows installers to simply connect pre-labeled wires to the connection box terminals rather than performing complex re-wiring of the AC unit and pump, dramatically reducing installation time and skill requirements while maintaining full BMS integration capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates safe and efficient installation of condensate pumps in AC units, preventing overflow and enabling integration with building management systems without re-wiring, reducing installation errors and ensuring reliable operation.
Implementation Method 1
a relay circuit configured to cut off power supply to the evaporator in the event of a high water level in the condensate reservoir
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
The connection box of the present invention provides a simple and safe method to integrate an AC unit and condensate pump into a larger building management system. This is possible because the circuit is configured to require high water level sensors are connected to the connection box in order for power to be provided to operate the AC unit. An installer only has to connect the external wires of the AC unit, condensate pump and building management system to the respective designated connection terminals within the connection box. The designated terminal connections provide a clearly labelled instruction to an installer and aid safe and proper installation of AC units and remove the need to re- wire the internal wiring of the AC unit.