Systems and methods for leak detection and refrigerant charging

Patent metadata

Field	Value
Publication number	US-11604019-B2
Application number	US-202016992872-A
Country	US
Kind code	B2
Filing date	Aug 13, 2020
Priority date	Aug 13, 2020
Publication date	Mar 14, 2023
Grant date	Mar 14, 2023

Abstract

A system for charging an outdoor unit with refrigerant includes a sensor configured to measure a refrigerant concentration and a user device configured to receive the measured refrigerant concentration. The system includes that the user device is configured to, in response to the measured refrigerant concentration exceeding a threshold, generate and display an alert on a user interface of the user device indicating the measured refrigerant concentration exceeds the threshold.

First claim

What is claimed is:

1. A charging system for charging a climate-control system with refrigerant, the charging system comprising:
a sensor configured to measure a refrigerant concentration; and
a user device configured to:
receive the measured refrigerant concentration; and
in response to the measured refrigerant concentration exceeding a threshold, generate and display an alert on a user interface of the user device indicating the measured refrigerant concentration exceeds the threshold,

wherein the user device is configured to be connected to a solenoid that controls refrigerant flow from a refrigerant container to a refrigerant manifold,
wherein the refrigerant manifold is connected to an outdoor unit of the climate-control system via a liquid line hose and a vapor line hose,
wherein refrigerant is transmitted between the refrigerant manifold and the outdoor unit via the liquid line hose and the vapor line hose,
wherein the user device is configured to transmit a control signal to a thermostat to actuate a blower in response to the measured refrigerant concentration exceeding the threshold, and
wherein the blower is disposed in an indoor air handler unit of an HVAC system and is configured to force air across a coil of a heat exchanger disposed within the indoor air handler unit.

2. The charging system of claim 1 further comprising a refrigerant scale, wherein the refrigerant container is located on the refrigerant scale and the refrigerant scale wireless transmits a measured refrigerant weight to the user device.

3. The charging system of claim 2 wherein:
the solenoid is arranged along the third hose, wherein the solenoid is configured to block refrigerant from flowing from the refrigerant container to the refrigerant manifold in response to the solenoid being actuated, wherein
the user device is configured to actuate the solenoid in response to the measured refrigerant concentration exceeding the threshold.

4. The charging system of claim 3 wherein:
the refrigerant manifold, the solenoid, the sensor, and the user device are configured to communicate wirelessly.

5. The charging system of claim 3 further comprising:
a first temperature probe connected to the first hose and configured to measure a first temperature;
a second temperature probe connected to the second hose and configured to measure a second temperature;
a first pressure sensor configured to measure a first pressure; and
a second pressure sensor configured to measure a second pressure, wherein the refrigerant manifold is configured to:
receive the first temperature, the second temperature, the first pressure, and the second pressure,
calculate a subcooling value and a superheat value based on the first temperature, the second temperature, the first pressure, and the second pressure,
open the solenoid for a threshold time in response to the subcooling value being below a subcooling threshold corresponding to the outdoor unit, and
open the solenoid for the threshold time in response to the superheat value being above a superheat threshold corresponding to the outdoor unit.

6. The charging system of claim 1 wherein:
the refrigerant manifold is configured to receive and display temperature data on an interface of the refrigerant manifold, and
the temperature data is received from a first temperature probe attached to the first hose and a second temperature probe attached to the second hose.

7. The charging system of claim 6 further comprising:
an outside air temperature sensor configured to measure an outside air temperature; and
a storage database configured to store, for a plurality of outdoor units, at least one of: a subcooling value, a superheat value, and an indoor coil temperature split value, wherein the user device is configured to:
obtain and storing the outside air temperature;
obtain, for the outdoor unit, at least one of: a corresponding subcooling value, a corresponding superheat value, and a corresponding indoor coil temperature split value from the storage database;
calculate at least one of: a present subcooling value, a present superheat value, and a present indoor coil temperature split value based on measurements of a first sensor and a second sensor; and
in response to at least one of: (i) the present subcooling value matching the corresponding subcooling value, (ii) the present superheat value matching the corresponding superheat value, and (iii) the present indoor coil temperature split value matching the corresponding indoor coil temperature split value, generate and display an alert indicating the outdoor unit is charged.

8. The charging system of claim 7 wherein:
the first sensor located to measure a return air temperature and humidity and the second sensor located to measure a supply air temperature and humidity, wherein the first sensor and the second sensor are configured to wirelessly transmit the return air temperature and humidity and the supply air temperature and humidity to the user device.

9. The charging system of claim 1 further comprising:
a lockout relay connecting a compressor of the outdoor unit to power, wherein the user device is configured to:
actuate the lockout relay to disconnect the compressor from the power in response to the measured refrigerant concentration exceeding the threshold.

10. The charging system of claim 1 further comprising:
a compressor of the outdoor unit, wherein the user device is configured to:
transmit a control signal to a thermostat to disconnect the compressor from power in response to the measured refrigerant concentration exceeding the threshold.

11. The charging system of claim 1 further comprising:
an indoor coil located within an indoor compartment, wherein:
the sensor is located within the indoor compartment,
the indoor coil is located indoors, and
the outdoor unit is located outdoors.

12. The charging system of claim 1 further comprising:
a wired sensor configured to measure a second refrigerant concentration at an indoor coil, wherein the user device:
receives the measured second refrigerant concentration from the wired sensor,
receives the measured refrigerant concentration from the sensor, and
in response to a difference between the measured second refrigerant concentration and the measured refrigerant concentration being greater than a calibration threshold, generates and displays an alert on the user device.

13. A method for charging a climate-control system with refrigerant, the method comprising:
measuring, via a sensor, a refrigerant concentration;
receiving, via a user device, the receive the measured refrigerant concentration;
in response to the measured refrigerant concentration exceeding a threshold, generating and displaying an alert on a user interface of the user device indicating the measured refrigerant concentration exceeds the threshold;
connecting the user device to a solenoid that controls refrigerant flow from a refrigerant container to a refrigerant manifold, wherein the refrigerant manifold is connected to an outdoor unit of the climate-control system via a liquid line hose and a vapor line hose;
transmitting refrigerant between the refrigerant manifold and the outdoor unit via the liquid line hose and the vapor line hose; and
transmitting, via the user device, a control signal to the thermostat to actuate a blower in response to the measured refrigerant concentration exceeding the threshold,
wherein the blower is disposed in an indoor air handler unit of an HVAC system and is configured to force air across a coil of a heat exchanger disposed within the indoor air handler unit.

14.

Assignees

• Emerson Climate Technologies

Inventors

• Alfano David A
• Morter Winfield S
• Butler Brian R

Classifications

• F25B2345/007

  characterised by the weighing of refrigerant or oil · CPC title

• F25B2345/003

  Control issues for charging or collecting refrigerant to or from a cycle · CPC title

• F25B2345/001

  Charging refrigerant to a cycle · CPC title

• F25B49/005

  of safety devices (F25B49/02 and F25B49/04 take precedence) · CPC title

• F25B45/00 Primary

  Arrangements for charging or discharging refrigerant · CPC title