Mini-Split Condensate Shutdown Control With Isolated Relay
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Solution Overview
Problem
Mini-split air conditioning 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 shut down the compressor without compromising the existing system's integrity.
Innovation Solution
A control system that includes a condensate sensor to detect a predetermined level of condensate in the drain pan and a solid state relay or switch to control the thermistor, ensuring the compressor is shut down without interfering with the power or communication links, using a battery-powered system with a low battery indicator and alarm to maintain system integrity.
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 supply, and control circuitry into a single integrated control board assembly that mounts directly on the air handler. This merging eliminates the need for separate discrete components and reduces overall system complexity while maintaining reliable condensate removal control.
Solution Approach 2:
The control board serves multiple functions simultaneously: it acts as the condensate sensor interface, overflow switch, power management unit with battery charging, compressor control relay, and system communication hub. This multi-functionality reduces the number of separate components needed and simplifies the overall system architecture.
2Reliability
If a battery-powered system is used for condensate control, then electrical isolation is improved, but device complexity increases
Solution Approach 1:
The battery pack, charging circuit, and control electronics are merged into a single integrated control board assembly. The battery compartment is built into the control board housing, and the charging circuit is integrated onto the same PCB, eliminating the need for separate external power management components.
Solution Approach 2:
The system includes automatic battery charging functionality where the control board draws power from the air handler during operation to recharge the battery. This self-charging mechanism eliminates the need for manual battery replacement or external charging equipment, reducing operational complexity.
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
Effectively controls the compressor operation in mini-split systems by isolating the condensate removal process, preventing disruptions to the power and communication links, and ensuring reliable condensate management without compromising the existing system's integrity.
Implementation Method 1
a condensate sensor disposed to sense when condensate within the condensate drain pan reaches a predetermined level
Implementation Method 2
The present invention employs a solid state relay or switch to control the thermistor without intruding or compromising the integrity of the power supply or communication link
Data Source
AI summary
A control system to selectively control the operation of the compressor of a mini-split air conditioning system including at least one remote evaporator operatively coupled to the compressor to receive refrigerant therethrough, a sensor to monitor the operation of the evaporator and to generate an operating control signal to turn-off the compressor when a predetermined operating condition is sensed at the evaporator and a condensate drain pan to receive or catch condensate from the evaporator, the control system comprising a condensate sensor disposed to sense condensate in the condensate drain pan at a predetermined level and to generate a condensate level signal fed to a battery powered control device including an isolated solid state relay coupled to the sensor by a control coupling device to generate a condensate level control signal fed to the sensor causing the sensor to generate the operating control signal fed to turn off the compressor when condensate within the condensate drain pan reaches the predetermined level.