Note: Descriptions are shown in the official language in which they were submitted.
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AIR CONDITIONING WIRING SYSTEM
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S.
Application Serial No. 12/694,437, filed by Mark Beste,
et al., on January 27, 2010, entitled "AIR CONDITIONING
WIRING SYSTEM," and incorporated herein by reference in
its entirety.
TECHNICAL FIELD
This application is directed, in general, to air
conditioning wiring and, more specifically, to a wiring
system for air conditioning units to reduce connections
errors in servicing the units.
BACKGROUND
Current air conditioning systems, especially rooftop
units have very disorganized wiring. The wiring
harnesses are complex and wires frequently cross each
other between the system components and the control
board. This leads to difficulty in manufacturing,
assembly and especially troubleshooting. Wires are
coupled to the system components and the control board in
what might appear to be a random fashion as dictated by
the design of the control circuit board and the placement
thereon of the wiring connectors.
This lack of organization leads to problems of
misconnection, especially by field technicians, as the
wiring connectors are, in many instances,
interchangeable. For example, wiring leads from a
temperature sensor may be connected to a connector
intended for a humidity sensor and visa versa. This can
lead to errors in servicing the unit, which in turn can
lead to a malfunction in the operation of the unit.
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SUMMARY
One aspect provides a wiring system for use in an
air conditioning system comprising a printed circuit
board having a perimeter and wiring receptacles located
proximate the perimeter and wiring connectors. In this
embodiment, at least some of the wiring receptacles
comprise two or more wiring sub-receptacles, and each of
the wiring sub-receptacles includes a slotted sub-
receptacle connection pattern. Furthermore, the slotted
sub-receptacle connection pattern of each of the wiring
sub-receptacles is different from every other sub-
receptacle connection pattern. Each of the wiring
connectors includes a ridged connection pattern that is
different from every other ridged connection pattern of
the wiring connectors, such that a given wiring connector
is receivable within only one of the wiring sub-
receptacles.
In another aspect, an air conditioning system
comprising a compressor, a controller, a thermostat and a
wiring system coupling the compressor, the controller and
the thermostat together is provided. In this embodiment,
the wiring system includes a printed circuit board having
a perimeter and wiring receptacles located proximate the
perimeter and wiring connectors. At least some of the
wiring receptacles comprise two or more wiring sub-
receptacles. Furthermore, each of the wiring sub-
receptacles includes a slotted sub-receptacle connection
pattern, such that the slotted sub-receptacle connection
pattern of each of the wiring sub-receptacles is
different from every other sub-receptacle connection
pattern. Each of the wiring connectors includes a ridged
connection pattern that is different from every other
ridged connection pattern of the wiring connectors, such
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that a given wiring connector is receivable within only
one of the wiring sub-receptacles.
In a third embodiment, a method of manufacturing a
wiring system for use in an air conditioning system is
provided. The method comprises providing a printed
circuit board and wiring connectors. The printed circuit
board has a perimeter and wiring receptacles located
proximate the perimeter wherein at least some of the
wiring receptacles comprise two or more wiring sub-
receptacles. Each of the wiring sub-receptacles includes
a slotted sub-receptacle connection pattern, such that
the slotted sub-receptacle connection pattern of each of
the wiring sub-receptacles is different from every other
sub-receptacle connection pattern. Each of the wiring
connectors includes a ridged connection pattern that is
different from every other ridged connection pattern of
the wiring connectors, such that a given wiring connector
is receivable within only one of the wiring sub-
receptacles.
BRIEF DESCRIPTION
Reference is now made to the following descriptions
taken in conjunction with the accompanying drawings, in
which:
FIG. 1 is a partial plan view of one embodiment of a
printed circuit board comprising a plurality of wiring
receptacles constructed according to the principles of
the present invention;
FIG. 2 is a close up plan view of a portion of the
printed circuit board of FIG. 1;
FIG. 3A is an isometric view of one embodiment of a
representative wiring connector for use with a sub-
receptacle of the type described in FIG. 2;
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FIG. 3B is an isometric view of the underside of the
wiring connector 300 of FIG. 3A;
FIG. 4 is an isometric view of one receptacle having
three sub-receptacles and matching three wiring
connectors;
FIG. 5A is a plan view of an inline wiring connector
constructed according to the principles of the present
invention; and
FIG. 5B is a plan view of the inline wiring
connector of FIG. 5A in its completed state.
DETAILED DESCRIPTION
Referring initially to FIG. 1, illustrated is a
partial plan view of one embodiment of a printed circuit
board 100 comprising a plurality of wiring receptacles
110-119 constructed according to the principles of the
embodiments discussed herein. The wiring receptacles
110-117 are located proximate the perimeter of the
printed circuit board 100 for ease of access to remove or
insert appropriate wiring connectors (not shown) The
prior art has typically relied on placing wiring
connectors to off-the-board components near the on-board
component being connected to. This results in
essentially random wiring to the board connections. In
many instances, the receptacles on the board are of the
same type and configuration, leading to the likelihood
for improper connection. In the present invention, the
receptacles are positioned near the perimeter of the
board thereby making them more readily accessible.
Additionally, the receptacles are functionally grouped so
that the wiring can be manufactured in bundles that
connect to off-the-board components. In one embodiment,
the wiring receptacles 110-119 are grouped functionally,
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e.g., wiring receptacle 110 groups all connections for an
economizer, wiring receptacle 111 groups all connections
for the high and low pressure compressor controls, wiring
receptacle 112 groups all connections for the blower deck
area, and wiring receptacle 113 groups all connections
for the system contactors and relays, etc. By way of
further example, wiring receptacle 114 may comprise
heating control contact points 121-126 which are as
follows: contact point 121 is 24VAC Common; contact point
122 is Electric Heat #1; contact point 123 is Electric
Heat #2; contact point 124 is 24VAC Common; contact point
125 is Electric Heat #3; and contact point 126 is
Electric Heat #4. Thus, all controls for up to four
electric heaters within the air conditioning system are
controlled through wiring receptacle 114. It should be
understood that the foregoing receptacle configuration
and its stated function is given as an example only and
that other receptacles configurations and functions, as
design parameters require are also applicable.
Each of the wiring receptacles 110-119 may comprise
one or more sub-receptacles, e.g., wiring receptacle 111
comprises three sub-receptacles llla-lllc. A sub-
receptacle as used herein is a receptacle that is
configured to receive a particular corresponding
connector and may include any number of pin and connector
configurations. In this instance, pins 1 and 2 (sub-
receptacle llla) of wiring receptacle 111 comprise a
reversing valve contact and 24 VAC power, respectively.
Pins 3, 4 and 5 (sub-receptacle lllb) comprise high
pressure compressor #1, 24 VAC Power and low pressure
compressor #1, respectively. Pins 6, 7 and 8 (sub-
receptacle 111c) comprise high pressure compressor #2, 24
VAC Power and low pressure compressor #2, respectively.
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In one embodiment, the printed circuit board 100 may
further comprise two or more wiring receptacles having
the same functional grouping. For example, receptacle
118 is for a Heating Sensor #1 and receptacle 119 is for
a Heating Sensor #2. Receptacle 118 is for use with one
model of air conditioning system and receptacle 119 is
for use with a different model of air conditioning
system. Thus, the printed circuit board 100 may be used
with more than one model of air conditioning system just
by configuring the printed circuit board 100 with the
necessary connections to prevent incorrect connection to
a particular wiring harness. While the pin count of
receptacles 118, 119 are the same, the receptacles 118,
119 will only accept a properly configured wiring
connector as will be explained in detail below. Each of
receptacle 118 and receptacle 119 comprise sub-
receptacles. For example, each receptacle 118 and 119
has two (2) sub-receptacles, 118a, 118b, 119a and 119b,
respectively, of five (5) pins each. From the left end
of each of receptacles 118a and 119a of FIG. 1, the pins
are: 1-5, and in one embodiment may be designated for a
Primary Limit Burner C (closed), Primary Limit Burner #
NC (normally closed), and Primary Limit Burner # NO
(normally open), Secondary Limit Burner # C and Secondary
Limit Burner # NC. From the left of each of the
receptacles 118b and 119b of FIG. 1 the pins are: 6-10
and in one embodiment may be designated for a Rollout
Switch Burner #, Rollout Switch Burner #, Cab Proof
Switch; Cab Proof Switch, Gas Valve Sensor #; where # is
1 (first - receptacle 118) or 2 (second - receptacle 119)
Burner.
Referring now to FIG. 2, illustrated is a close up
plan view of a portion of the printed circuit board 100
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of FIG. 1 especially showing receptacles 118, 119 and
their respective sub-receptacles 118a, 118b, 119a and
119b. Note that while there are 10 pins in each
receptacle (5 pins per sub-receptacle), there is a
combination of slots 201-219 at the periphery of each
sub-receptacle 118a, 118b, 119a and 119b. Note that sub-
receptacle 118a has slots 201-207, sub-receptacle 118b
has slots 208-210, sub-receptacle 119a has slots 211-216,
and sub-receptacle 119b has slots 217-219. Closer
observation of the slots 201-219 show that they form
specific patterns with respect to the sub-receptacles of
which they are a part. The slots can be on either or
both sides of a pin. For example, pin 1 of sub-
receptacle 118a has four slots 201, 202, 204 and 205
associated therewith, thereby utilizing all four
available slot positions. Pin 4 of sub-receptacle 118a
has a single slot 206 associated therewith and pin 5 of
sub-receptacle 118a has two slots 203 and 207, one on
either side of pin 5 and associated therewith. In
contrast, pin 1 of sub-receptacle 119a has two slots 211
and 213 associated therewith. Pin 2 of sub-receptacle
119a has one slot 214 associated therewith and pin 3 of
sub-receptacle 119a has a single slot 212 associated
therewith. Pin 4 of sub-receptacle 119a has one slot 215
associated therewith and pin 5 of sub-receptacle 119a has
a single slot 216 associated therewith. Note that
although some of the pins of sub-receptacle 118a have the
same number of slots associated with the corresponding
pin of sub-receptacle 119a, the placement of the slots in
relation to the pin is different, i.e., pin 4 on each of
sub-receptacles 118a, 119a each have one slot associated
therewith. However, the location of the slot in relation
to the pin is different for each sub-receptacle. As seen
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from the foregoing, there is presented a system where the
connection pattern of any given sub-receptacle is
different from the connection pattern of every other sub-
receptacle. This provides the benefit of simplifying
servicing of the unit and reduces errors in electrically
connecting components together.
Referring now to FIG. 3A and FIG. 3B, illustrated in
FIG. 3A is an isometric view of one embodiment of a
representative wiring connector 300 for use with a sub-
receptacle 360 of the type described above. FIG. 3B
illustrates the underside of the wiring connector 300 of
FIG. 3A. The wiring connector 300, as illustrated, is
for a three wire sub-receptacle. The wiring connector
300 comprises a connector body 310, wire access ports
321-323, contact screws 331-333 and ridge positions 341-
346. Of the six ridge positions 341-346 shown, only one
ridge position 342 has a ridge thereat. FIG. 3B
illustrates an additional six ridge positions 347-352 on
the underside of the wiring connector 300. For the
purpose of this discussion, two of the additional six
ridge positions 347-352 comprise a ridge, i.e., positions
347 and 350. The wiring connector 300 is preferably of
molded plastic with metallic wiring terminals (not shown)
therein. To employ the wiring connector 300, appropriate
wires (not shown) are stripped from a pre-measured wiring
harness and inserted into the appropriate wire access
ports 321-323. The contact screws 331-333 are then
tightened onto the wires. Of course, the wiring
connector 300 could also be molded in place on
appropriate wires if desired. The wiring connector 300
is then ready to couple to the appropriate sub-receptacle
360. It can be seen by one who is of ordinary skill in
the art that ridge 342 cooperates with slot 363 and
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ridges 347 and 350 cooperate with slots 361 and 362,
respectively.
Referring now to FIGS. 1 and 3, the wiring
receptacle 114 comprises wiring sub-receptacles 114a and
114b, each having three pins or contact points.
Examination of the slot pattern of wiring sub-receptacles
114a and 114b indicate that the wiring connector 300 can
not be inserted in any of the wiring sub-receptacles
114a, 114b as the ridges and slots do not match either of
these patterns. Thus, the wiring connector 300 is
prevented from being incorrectly connected to the board
100. Additionally, wiring sub-receptacles 114a, 114b may
further each have a distinct color, e.g., blue, red,
etc., that is matched with the same color of the
appropriate wiring connector (not shown) . This color
matching of wiring connector to sub-receptacle is
continued throughout the printed circuit board 100. This
additionally assists the technician in choosing the
correct sub-receptacle for inserting the wiring
connector.
Referring now to FIG. 4, illustrated is an isometric
view of one receptacle 400 having three sub-receptacles
400a, 400b, 400c and the matching three wiring connectors
411, 412, 413, respectively. FIG. 4 clearly shows that
sub-receptacle 400a has two pin positions, sub-receptacle
400b has six pin positions and sub-receptacle 400c has
two pin positions. Notice also that the colors of the
sub-receptacles 400a, 400b, 400c match the colors of the
three wiring connectors 411, 412, 413. Furthermore,
labels 421 on each of the pin positions of the three
wiring connectors 411, 412, 413 correspond to labels 422
on the matching sub-receptacles 400a, 400b, 400c. Note
also that slots 431a-431c in sub-receptacle 400a have
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matching ridges 432a-432c (432c not visible) on wiring
connector 411. In like manner slots 431d-431f and ridges
432d-432f match between sub-receptacle 400b and wiring
connector 412. Also, slot 431g in sub-receptacle 400c
has a matching ridge 432g on wiring connector 413.
Referring now to FIGURE 5A, illustrated is a plan
view of an inline wiring connector 500 that may be used
in connection with the embodiments discussed above. The
female (first) inline wiring connector 501 comprises a
number of wire positions wherein one end 530 of the wires
are connected to a sub-connector (not shown) for
connection to the printed circuit board 100 as described
above. The other end (not visible) of the wires 510 are
coupled to contacts (not visible) within the first inline
wiring connector 501. The male (second) inline wiring
connector 502 comprises wire access ports 511-516,
contact screws 521-526 and ridges 531-532. The first
inline wiring connector 501 further comprises slots (not
visible) that mate with the ridges 531, 532. Of course
other patterns of slots and ridges may be employed to
assure that only the correct second connector is coupled
to the matching first connector in the same manner as
described in FIGURE 4. Additionally, the matching first
and second inline wiring connectors may be matching color
coded and both labeled for positive identification.
Referring now to FIGURE 5B, illustrated is a plan
view of the inline wiring connector 500 of FIGURE 5A in
its completed state. The second inline wiring connector
502 has a cover 503 thereon that includes a spring-loaded
latching mechanism 504 that securely captures and holds
the first inline wiring connector 501. One who is of
skill in the art is familiar with the mechanism by which
inline connectors lock together.
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Thus, a wiring system for an air conditioning system
has been des-cribed such that wiring connectors are
individually coded by virtue of ridges that cooperate
with slots in wiring receptacles on a printed circuit
board to prevent incorrect wiring connections. The
wiring connectors and wiring receptacles further comprise
matching colors and labels to enhance correct
identification and proper installation. An inline wiring
connector utilizing the same slot and ridge, color and
label coding is likewise described.
Those skilled in the art to which this application
relates will appreciate that other and further additions,
deletions, substitutions and modifications may be made to
the described embodiments.
