Abstract: A method of manufacturing a shell from sheet metal for a room air conditioner/heat pump is shown. The sheet metal is stamped and formed to a U-shaped rectangular shell with open ends and a shell brace. Flanges on the outer edge of the U-shaped rectangular shell overlap at corners with (a) adjacent flanges or (b) the shell brace. Both the U-shaped rectangular shell and shell brace are inserted into an assembly machine where the corners are clinched and punched. The outermost flange at each corner is punched to a fixed diameter, but the innermost flange or the shell brace is only punched to a conical shape. Screws are inserted at each corner that pass through the fixed diameter to threadably engage only the conical shape of the innermost flange or shell brace.

Abstract: A pre-charged heating/cooling system is shown for installation by unlicensed personnel. An outside unit includes an outside coil, outside fan, compressor and a reversing valve. An inside unit has an inside coil, inside fan for drawing air through the inside coil and discharging the conditioned air into the enclosed space, and a power cord connection. Electrical connections between the inside unit and the outside unit are secured in position by an electrical disconnect cover. A covering box covers both the electrical and refrigerant connections to the outside unit.

Abstract: A universal control system is provided for a room air conditioner or heat pump that has a number of sensor inputs. An electronic control system with a microcontroller and microcomputer are used to provide a large number of operations that can be performed by (1) manufacturer, (2) end users and (3) maintenance personnel. The manufacturer can load different versions of a software program to match the unit. The end user can program in a large number of different conditions or schedules the end user finds desirable, plus the end user is advised of maintenance requirements or faults. The maintenance personnel may perform diagnostics, determine fault history, upload improved or replacement software, as well as the numerous maintenance functions normally performed by maintenance personnel. Remote control is provided for changing operating conditions of the air conditioner/heat pump.

Abstract: A universal control system is provided for a room air conditioner or heat pump that has a number of sensor inputs. An electronic control system with a microcontroller and microcomputer are used to provide a large number of operations that can be performed by (1) manufacturer, (2) end users and (3) maintenance personnel. The manufacturer can load different versions of a software program to match the unit. The end user can program in a large number of different conditions or schedules the end user finds desirable, plus the end user is advised of maintenance requirements or faults. The maintenance personnel may perform diagnostics, determine fault history, upload improved or replacement software, as well as the numerous maintenance functions normally performed by maintenance personnel.

Abstract: A room air conditioner and/or heat pump is shown having a compressor, indoor coil, accumulator, expansion device and reversing valve for changing between a cooling cycle and a heating cycle. Intake louvers direct return air over the entire indoor coil for maximum heat transfer. Discharge louvers are curved upward to prevent short cycling while still being totally adjustable, up and down, right and left. Adjustment posts are anchored to a clip and are adjustable for right or left discharge of air and up or down discharge. Single handles control both the right or left discharge through a rear set of louvers and up or down discharge through a front set of louvers. A no circulation area prevents short cycling and curved edges prevent turbulence in air flow through louvers.