HVAC Mini-Split Coupling Harness for Condensate Overflow Detection
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Solution Overview
Problem
Mini-split HVAC systems face challenges in condensate removal due to limited space for overflow switches and condensate sensors, which can disrupt the power supply and communication links, requiring an electrically isolated battery-powered system to prevent system shutdowns.
Innovation Solution
A control system using a solid state relay or switch to manage the thermistor without compromising the power supply or communication links, incorporating a self-contained alarm coupling harness with electrically-coupled interfaces for the thermistor, condensate overflow sensor, and electronic control device to selectively control the compressor based on alarm conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a condensate sensor and overflow switch are installed in the mini-split system, then condensate removal control is improved, but the system complexity increases and space requirements are not met
Solution Approach 1:
The patent combines the condensate sensor, overflow switch, battery power source, and control circuitry into a single integrated control board assembly that mounts within the air handler. This merging eliminates the need for separate discrete components and their associated wiring, thereby improving condensate removal control while avoiding increased system complexity.
Solution Approach 2:
The control board serves multiple functions: it monitors condensate levels via the sensor, detects overflow conditions via the switch, provides power to these components through the integrated battery, and interfaces with the mini-split system's control electronics. This multi-functionality allows comprehensive condensate management within the limited space of the air handler without adding separate dedicated systems.
2Adaptability or versatility
If the air handler is made compact for wall mounting, then installation flexibility is improved, but space for overflow switches and condensate sensors is reduced
Solution Approach 1:
The patent merges the condensate sensor, overflow switch, and their supporting electronics into a single compact control board assembly. This integration reduces the total space required compared to having separate mounted components for each function, enabling the air handler to maintain a compact wall-mounted form factor while still accommodating all necessary condensate management components.
Solution Approach 2:
The control board assembly nests multiple functional components (sensor, switch, battery, circuitry) within a single housing or mounting structure inside the air handler. This nesting arrangement maximizes the use of available internal space, allowing the air handler to remain compact for wall mounting while providing adequate space for all condensate monitoring and control functions.
Data Source
AI summary
A coupling harness useful with a HVAC mini-split system includes a first interface connected to a thermistor, a second interface connected to a condensate overflow sensor and a control device interface connected to a HVAC electronic control device. The first and second interfaces can notify the control device interface of the existence of an alarm condition of the thermistor and condensate overflow sensor, respectively. The control device interface can actuate the HVAC electronic control device in response to such notifications that an alarm condition exists for the thermistor or condensate overflow sensor.