Systems and Methods for Air Temperature Control Including A2L Sensors

Abstract

The present invention provides a system for detecting an amount of A2L refrigerant in an air temperature controller using an A2L refrigerant, and a method of installing a configuration of A2L sensors in the air temperature controller using an A2L refrigerant. The system includes an A2L control board, a first A2L sensor, and a second A2L sensor. The first A2L sensor and the second A2L sensor are coupled in series and electrically coupled to the A2L control board. Each of the first A2L sensor and the second A2L sensor include sensing components configured to detect the amount of A2L refrigerant.

What is claimed is: 
     
         1 . An A2L sensor comprising:
 a sensing component configured to detect an amount of A2L refrigerant;   a bus connector input;   a bus connector output;   a sensor relay electrically disposed between the bus connector input and the bus connector output; and   a sensor feedback port electrically disposed between the sensor relay and the bus connector output.   
     
     
         2 . The A2L sensor of  claim 1 , wherein the bus connector input is electrically coupled to an A2L control board and receives power from the A2L control board. 
     
     
         3 . The A2L sensor of  claim 2 , wherein the bus connector output is electrically coupled to a second A2L sensor. 
     
     
         4 . The A2L sensor of  claim 1 , wherein a default status of the sensor relay is open. 
     
     
         5 . The A2L sensor of  claim 4 , wherein the sensor relay is configured to close when the A2L sensor passes a self-diagnostic test. 
     
     
         6 . The A2L sensor of  claim 2 , wherein the sensor feedback port is configured to transmit a feedback signal to the A2L control board when the sensor relay is closed. 
     
     
         7 . A system for controlling air temperature in a building, the system comprising:
 an outdoor unit disposed outside the building;   an indoor unit disposed inside the building, the indoor unit comprising:
 a heat exchanger that uses an A2L refrigerant; 
 a blower disposed within the indoor unit; 
 an indoor control board electrically coupled to the blower and the outdoor unit; 
 one or more A2L sensors configured to detect an amount of the A2L refrigerant in the indoor unit; 
 a transformer; and 
 an A2L control board electrically coupled to the transformer, the one or more A2L sensors, the indoor control board and the blower, wherein the A2L control board is configured to receive power from the transformer; 
   wherein the A2L control board is configured to power on the blower and power off the indoor control board and the outdoor unit when the one or more A2L sensors detect the amount of the A2L refrigerant exceeds a leak threshold.   
     
     
         8 . The system of  claim 7 , wherein:
 the A2L control board includes a first relay disposed between the transformer and the indoor control board, wherein the blower and the outdoor unit receive power from the A2L control board via the indoor control board when the first relay is closed;   the A2L control board includes a second relay disposed between the transformer and the blower, wherein the blower receives power from the A2L control board when the second relay is closed, and   each of the one or more A2L sensors comprises a bus connector input, a bus connector output, a sensor relay electrically disposed between the bus connector input and the bus connector output, and a sensor feedback port electrically disposed between the sensor relay and the bus connector output.   
     
     
         9 . The system of  claim 8 , wherein:
 the A2L control board is configured to power off the indoor control board and the outdoor unit by opening the first relay; and   the A2L control board is configured to power on the blower by closing the second relay.   
     
     
         10 . The system of  claim 9 , wherein:
 the blower includes a blower motor;   the A2L control board is directly coupled to an input lead on the blower motor;   the transformer produces 24 volts of alternating current;   when the second relay of the A2L control board is closed, the lead on the blower motor is configured to receive 24 volts of alternating current; and   the blower motor is configured to power on when it receives 24 volts of alternating current on the lead on the blower motor.   
     
     
         11 . The system of  claim 9 , wherein:
 a first default orientation for the first relay of the A2L control board is open;   a second default orientation for the second relay of the A2L control board is closed; and   if the A2L control board loses power, the first relay and the second relay are configured to revert to the first default orientation and the second default orientation, respectively.   
     
     
         12 . The system of  claim 7 , wherein:
 the A2L control board further includes a buzzer and an L E D; and   the A2L control board is configured to power on the buzzer and LE D when the one or more A2L sensors detect the amount of the A2L refrigerant exceeds the leak threshold.   
     
     
         13 . The system of  claim 7 , wherein:
 the one or more A2L sensors are disposed within the indoor unit;   the indoor unit further includes an evaporator coil; and   the one or more A2L sensors are coupled to the evaporator coil.   
     
     
         14 . A method of installing an air temperature controller in a building, the method comprising:
 disposing an outdoor unit outside the building;   disposing an indoor unit inside the building, the indoor unit having a heat exchanger that uses A2L refrigerant;   disposing a blower within the indoor unit;   disposing an indoor control board within the indoor unit;   electrically coupling the indoor control board to the blower and the outdoor unit;   disposing one or more A2L sensors within the indoor unit, the one or more A2L sensors configured to detect an amount of the A2L refrigerant within the indoor unit; and   disposing a transformer within the indoor unit;   electrically coupling an A2L control board to the transformer, the one or more A2L sensors, the indoor control board and the blower, wherein the A2L control board is configured to receive power from the transformer;   detecting the amount of the A2L refrigerant exceeds a leak threshold using the one or more A2L sensors; and   after detecting that the amount of the A2L refrigerant exceeds the leak threshold:
 powering on the blower using the A2L control board; and 
 powering off the indoor control board and the outdoor unit using the A2L control board. 
   
     
     
         15 . The method of  claim 14 , wherein:
 the A2L control board includes a first relay disposed between the transformer and the indoor control board, wherein the blower and the outdoor unit receive power from the A2L control board via the indoor control board when the first relay is closed;   the A2L control board includes a second relay disposed between the transformer and the blower, wherein the blower receives power from the A2L control board when the second relay is closed; and   each of the one or more A2L sensors comprises a bus connector input, a bus connector output, a sensor relay electrically disposed between the bus connector input and the bus connector output, and a sensor feedback port electrically disposed between the sensor relay and the bus connector output.   
     
     
         16 . The method of  claim 15 , further comprising:
 powering off the indoor control board and the outdoor unit by opening the first relay using the A2L control board; and   powering on the blower by closing the second relay using the A2L control board.   
     
     
         17 . The method of  claim 16 , further comprising:
 coupling the A2L control board to an input lead on a blower motor of the blower, wherein the blower includes the blower motor, wherein the blower motor is configured to power on when it receives 24 volts of alternating current on the input lead of the blower motor, and wherein the transformer produces 24 volts of alternating current.   
     
     
         18 . The method of  claim 16 , further comprising:
 if the A2L control board loses power:
 reverting the first relay to a first default orientation; and 
 reverting the second relay to a second default orientation, wherein:
 a first default orientation for the first relay of the A2L control board is open; and 
 a second default orientation for the second relay of the A2L control board is closed. 
 
   
     
     
         19 . The method of  claim 14 , further comprising:
 powering on a buzzer and an L E D when the one or more A2L sensors detect the amount of the A2L refrigerant exceeds the leak threshold, wherein the buzzer and the LED are disposed on the A2L control board.   
     
     
         20 . The method of  claim 14 , further comprising:
 disposing the one or more A2L sensors within the indoor unit; and   coupling the one or more A2L sensors to an evaporator coil, wherein the indoor unit includes the evaporator coil.