U.S. patent application number 14/048017 was filed with the patent office on 2014-02-06 for interactive control system for an hvac system.
This patent application is currently assigned to Emerson Electric Co.. The applicant listed for this patent is Emerson Electric Co.. Invention is credited to William P. Butler, James P. Garozzo.
Application Number | 20140034284 14/048017 |
Document ID | / |
Family ID | 46326137 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140034284 |
Kind Code |
A1 |
Butler; William P. ; et
al. |
February 6, 2014 |
Interactive Control System for an HVAC System
Abstract
An interactive system for controlling an HVAC system includes a
thermostat for initiating HVAC system operation in a full-capacity
or reduced-capacity mode of operation, and a controller for an
outside condenser unit having condenser fan and compressor motors.
The controller may operate the compressor in a full-capacity or
reduced-capacity mode. A controller for an indoor blower unit
having a blower fan motor may operate the blower fan motor in a
full-capacity or reduced-capacity mode. A communication means is
provided for transmitting information between the outside condenser
unit controller and indoor blower controller. The indoor blower
controller responsively controls blower fan motor operation in a
full-capacity or reduced-capacity mode based on the information
received from the outdoor unit controller. The outdoor unit
controller responsively controls compressor operation in a
full-capacity or reduced-capacity mode based on the information
received from the indoor blower controller.
Inventors: |
Butler; William P.; (St.
Louis, MO) ; Garozzo; James P.; (St. Louis,
MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Emerson Electric Co. |
St. Louis |
MO |
US |
|
|
Assignee: |
Emerson Electric Co.
St. Louis
MO
|
Family ID: |
46326137 |
Appl. No.: |
14/048017 |
Filed: |
October 7, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11526268 |
Sep 22, 2006 |
8550368 |
|
|
14048017 |
|
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|
|
11063806 |
Feb 23, 2005 |
7296426 |
|
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11526268 |
|
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Current U.S.
Class: |
165/207 |
Current CPC
Class: |
Y02B 30/743 20130101;
F24F 11/30 20180101; F25B 49/02 20130101; G05D 23/1904 20130101;
F24F 11/54 20180101; Y02B 30/70 20130101; F25B 2700/21152 20130101;
F25B 2600/025 20130101; F25B 2700/2104 20130101; F25B 2700/2106
20130101; F24F 11/52 20180101; F25B 2700/151 20130101; F25B
2600/111 20130101 |
Class at
Publication: |
165/207 |
International
Class: |
F24F 11/00 20060101
F24F011/00 |
Claims
1. An interactive system for controlling at least a heating
apparatus in a climate control system having a thermostat and at
least one controller for controlling at least a compressor of an
air conditioner system, the interactive system comprising: a
heating controller for controlling operation of the heating
apparatus; and a two-wire communication network for transmitting
data signals to and from the thermostat, the heating controller and
the at least one controller for controlling at least the
compressor, where the data signals being transmitted include
information identifying a destination controller that a data signal
is intended for; wherein the heating controller is configured to
receive data signals that include information about operation of at
least one component within the air conditioning system, and the
heating controller is configured to modify operation of at least an
air circulator blower in response to the information about
operation of the at least one component within the air conditioning
system.
2. The interactive system of claim 1 wherein the information about
operation of the at least one component indicates the air
conditioner compressor is only capable of operating at one of a
high capacity or a reduced capacity mode of operation, and the
heating controller responsively operates the air circulator blower
at a capacity level that corresponds to the high capacity or
reduced capacity mode of operation of the compressor.
3. The interactive system of claim 1 wherein the information about
operation of the at least one component indicates the air
conditioner compressor is only capable of operating intermittently,
and the heating controller responsively operates the air circulator
blower intermittently to correspond to the intermittent compressor
operation.
4. The interactive system of claim 1 wherein the heating controller
is capable of modifying an operating capacity of the air circulator
blower in response to receiving a sensor-transmitted signal that is
intended for the thermostat and that includes information about a
sensed parameter that is out of a designated range.
5. The interactive system of claim 4 wherein the sensor is a carbon
monoxide sensor, and the sensed parameter indicates the presence of
carbon monoxide gas at a level predetermined as harmful.
6. An interactive controller for controlling the operation of at
least an air circulator blower of a climate control system, the
interactive controller comprising: a connection means for
connection to a two-wire network for permitting communication with
a thermostat and a controller for controlling an air conditioner
compressor, wherein the interactive controller is connected to the
thermostat and air conditioner compressor controller only through
the connection means to the two-wire network; and a microprocessor
capable of monitoring signals being communicated via the two-wire
network, the microprocessor being capable of modifying the
operating capacity of the air circulator blower in response to
receiving a signal that is addressed to the thermostat or the air
conditioner compressor controller, and includes information about
an operating parameter of at least one component in the climate
control system.
7. The interactive controller of claim 6, capable of reducing the
operating capacity of the air circulator blower in response to
receiving a signal intended for the thermostat that includes
information of a reduced operating capacity of the air conditioner
compressor.
8. The interactive controller of claim 7, capable of reducing the
operating capacity of the air circulator blower regardless of any
signal being sent by the thermostat.
9. An interactive controller for controlling the operation of at
least an air circulator blower of a climate control system, the
interactive controller comprising: a connection means for
connection to a two-wire network for permitting communication with
one or more controllers within the climate control system that are
connected to the network; and a microprocessor capable of
monitoring communication signals through the two-wire network upon
connection to the two-wire network, and capable of identifying
other controllers that are transmitting signals via the two-wire
network, where the interactive controller and the network are not
configured in a master-slave configuration; wherein the interactive
controller is capable of modifying operation of the operating
capacity of the air circulator blower in response to detecting a
signal addressed to another controller that includes information
about an operating parameter of at least one component in the
climate control system.
10. The interactive controller of claim 9, capable of establishing
operation of the air circulator blower in response to receiving a
signal transmitted by a carbon monoxide sensor that is intended for
a communication coordinator controller connected with the network,
where the transmitted signal indicates the presence of a harmful
level of carbon monoxide gas.
11. The interactive controller of claim 9 wherein the controller
for controlling the operation of at least an air circulator blower
is capable of reducing the operating capacity of the air circulator
blower in response to receiving a signal intended for the
thermostat controller that includes information of a reduced
operating capacity of the air conditioner compressor.
12. An interactive system for controlling a climate control system,
comprising: a two-wire network; and a plurality of system
controllers configured to transmit signals to and receive signals
from one another via the two-wire network absent any control by a
master controller, where each system controller is capable of
listening to signals sent by any one of the other system
controllers and addressed to any other of the other system
controllers via the network, where the signals include information
about operation of one or more components in the climate control
system, and where a given one of the system controllers is capable
of responsively modifying operation of at least one climate control
system component that the given system controller has control over,
the modifying based on the information about the operation of the
one or more components in the climate control system.
13. The interactive system of claim 12, wherein the system
controllers comprise controllers connected into the network in the
course of installing new components in the climate control
system.
14. The interactive system of claim 12, wherein a single signal
transmission intended for a specific one of the system controllers
includes information upon which a plurality of the system
controllers base modification of operation of a plurality of
components of the climate control system.
15. The interactive system of claim 12, wherein one of the system
controllers modifies operation of one of the climate system
components in response to one of the signals, regardless of a
request by a thermostat controller of the climate control
system.
16. The interactive system of claim 12, wherein one of the system
controllers is a controller of an air circulator blower and is
capable of reducing an operating capacity of the air circulator
blower regardless of any signal being sent by a thermostat of the
climate control system.
17. The interactive system of claim 12, wherein one of the system
controllers is a heating controller capable of modifying an
operating capacity of an air circulator blower in response to
receiving a sensor-transmitted signal that is intended for a
thermostat of the climate control system.
18. The interactive system of claim 17, wherein the
sensor-transmitted signal includes information about a sensed
parameter that is out of a designated range.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 11/526,268 filed Sep. 22, 2006, which is a
continuation-in-part of U.S. patent application Ser. No. 11/063,806
filed Feb. 23, 2005. The entire disclosures of the above
applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to controllers for
interactively controlling an HVAC system, and more particularly to
an integrated system of individual controllers for interactively
controlling various components in the HVAC system.
BACKGROUND
[0003] Many present HVAC systems employ a plurality of controllers
for communicating information within a master/slave network, in
which a "master" thermostat or similar central controller is the
master that coordinates communication between the various slave
components within the HVAC system. Such networks require various
subordinate controllers to be configured for communication with and
control by a master thermostat or communication controller, without
which the system's subordinate controllers can not communicate to
operate various components of the HVAC system. Thus, the various
HVAC component controllers rely on the master controller to
communicate operating instructions and system diagnostics, and each
controller does not independently manage its operation based on
diagnostic information transmitted by other subordinate HVAC
controllers.
SUMMARY
[0004] The present disclosure provides for an interactive control
system for controlling the operation of various controllers in an
HVAC system. The interactive system includes a thermostat for
initiating the operation of the HVAC system in either a full
capacity mode of operation or at least one reduced capacity mode of
operation, and a controller for an outside condenser unit having a
condenser fan motor and a compressor motor, the controller being
capable of operating the compressor in a full capacity mode and at
least one reduced capacity mode. The system also includes a
controller for an indoor blower, which is capable of operating a
blower fan motor in a full capacity mode and in at least one
reduced capacity mode. The interactive system further includes a
communication means for transmitting information between the
outside condenser unit controller and the indoor blower controller
relating to the operation of the condenser unit components and the
blower components, where the indoor blower controller responsively
controls the operation of the blower fan motor in a full capacity
mode or a reduced capacity mode based on the information received
from the outdoor unit controller. The outdoor unit controller may
responsively control the operation of the compressor in a full
capacity mode or a reduced capacity mode based on the information
received from the indoor blower controller.
[0005] In one aspect of the present disclosure, some embodiments of
an interactive system may include at least two controllers that
communicate with each other to provide a method of controlling the
operation of an HVAC system in either a full capacity mode of
operation or a reduced capacity mode of operation based on the
communication between the at least two controllers of information
relating to the operation of various components in the HVAC
system.
[0006] In another aspect of the present disclosure, some
embodiments of an interactive system having two or more controllers
are provided that are capable of detecting component operating
parameters and communicating the operating parameter information to
at least one other controller to enable confirming diagnostics for
predicting potential component failure or required servicing. These
and other features and advantages will be in part apparent, and in
part pointed out hereinafter.
DRAWINGS
[0007] FIG. 1 is an illustration of a building with one embodiment
of an interactive control system for an HVAC system according to
principles of the present disclosure;
[0008] FIG. 2 is a functional block diagram of one embodiment of an
interactive system for controlling an HVAC system; and
[0009] FIG. 3 is a schematic of one embodiment of an interactive
system;
[0010] FIG. 4 is a schematic diagram of a fourth embodiment of an
interactive HVAC system;
[0011] FIG. 5 is a view of one embodiment of a thermostat
controller displaying operating information in accordance with
principles of the present disclosure;
[0012] FIG. 6 is a view of the thermostat controller of FIG. 5,
displaying operating information in accordance with principles of
the present disclosure;
[0013] FIG. 7 is a view of the thermostat controller of FIG. 5,
displaying a menu option for programming the thermostat or other
interactive controllers in accordance with principles of the
present disclosure; and
[0014] FIG. 8 is a view of the thermostat controller of FIG. 5,
displaying programmed settings of another thermostat controller in
accordance with principles of the present disclosure.
[0015] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0016] Various embodiments of interactive systems are provided that
include a plurality of interactive controllers for controlling the
operation of a climate control system, such as that shown in FIG.
1. As shown and described, the climate control system may include
at least one air conditioner comprising an outdoor condenser unit
22. In one embodiment of an interactive system, the climate control
system has a controller 24 for the outdoor air conditioner unit, at
least one indoor blower unit 26 having an indoor blower controller
28 and at least one thermostat 30 for directing the operation of
the various units. The climate control system may further include a
heating unit 32, such as an electric or gas-fired furnace, and a
related furnace controller 34. The climate control system may
include an air circulator blower unit 26 having a blower motor 36.
The circulator blower motor 36 may optionally include a blower
motor controller 38. The thermostat 30 is capable of sensing the
temperature within the space and responsively initiating operation
of an air conditioning or furnace unit when the sensed temperature
is more than a predetermined amount above or below a set point
temperature of the thermostat 30. In response to a thermostat
signal request for cooling, the outdoor unit controller 24 will
control the switching of power to both a condenser fan motor 40 and
a compressor motor 42, and the indoor blower controller 28 controls
the blower motor 36 or the blower motor controller 38 to provide
for air conditioning operation. Likewise, when the thermostat 30
signals a request for heating, the furnace controller 34 controls
the activation of the furnace 32 and the blower motor controller 38
controls the blower motor 36 or the blower motor controller 38 to
provide for heating operation. Each of the various controllers may
be connected to either a high voltage power source or a low voltage
power source. The outdoor unit controller 24 may be configured to
control a multi-capacity compressor motor 42 as well as a variable
speed condenser fan motor 40. Likewise, the indoor air
handler/blower controller 28 and the furnace controller 34 may be
configured to establish multiple operating speeds of the circulator
blower motor 36. The optional blower motor controller 38 may also
include an integral inverter driver for enabling variable speed
control of the blower motor.
[0017] In the various embodiments of an interactive system, the
various controllers that control individual components within the
climate control system are further capable of receiving
communication from other controller and components, to
interactively control and improve the operation of the climate
control system. For example, some embodiments a climate control
system may include an indoor blower controller 28 and an outdoor
unit controller 24 that communicate via a network, where the
controllers 24 and 28 do not communicate with a thermostat 30 via
the network. The thermostat 30 may be a conventional thermostat
that requests low stage cooling by sending a conventional 24 volt
signal via a "Y1" line to the indoor blower controller 28 and to
the outdoor unit controller 24. During the request for cooling from
the thermostat 30, the indoor blower controller 28 may experience a
blower motor failure and communicate the fault to the outdoor unit
controller 24, which would responsively discontinue operation of
the outdoor unit to protect the compressor 40 from being damaged.
In this example, the communication between the individual
controllers 24 and 28 mitigates damage by discontinuing operation,
regardless of whether the conventional thermostat 30 is still
calling for low stage cooling operation. It should be noted that
the indoor and outdoor controllers 28 and 24 may be used with
either a conventional thermostat 30, or an interactive thermostat
30 that is configured to be connected to a network 48. An
interactive thermostat that is connected to the communication
network 48 may send a cooling request signal via the network 48,
rather than through the conventional 24 volt wire connections to
the indoor blower unit controller 28 and outdoor unit controller
24. Where an interactive thermostat 30 is connected to the
communication network 48, the thermostat would be capable of
receiving the blower motor fault signal and responsively
discontinuing its cooling request signal and notifying the occupant
of the blower motor failure. Additionally, the thermostat 30 may
also communicate the fault signal to an outside location, such as a
service contractor or a system monitoring service provider.
[0018] One communication means that may be employed by the various
embodiments is shown in FIG. 2. The communication means includes a
two-wire peer-to-peer network 48, such as an RS-485 peer-to-peer
Local Area Network, but may alternatively include any other
comparable network suitable for use in a peer-to-peer arrangement.
An RS-485 network is a two-wire, multi-drop network that allows
multiple units to share the same two wires in sending and receiving
information. The two-wire network 48 connects to a transmitter and
receiver of each controller in the HVAC system (up to 32 controller
units). The controllers are always enabled in the receiver mode,
monitoring the network 48 for information. Only one transmitter can
communicate or occupy the network 48 at a time, so each individual
controller may be configured at the time of manufacture to transmit
at a fixed time period after the last transmission, where each
controller has a time period that is unique to that controller.
Thus, after one controller completes its transmission, another
controller will wait for the prescribed time period before
transmitting its information. In this manner, collisions of data
transmission from different controllers may be avoided. The
transmissions may also include leader information at the beginning
of each transmission to identify at least the transmitting
controller.
[0019] The network may also be configured to provide for
communication with an outside location 50 (e.g. outside the home)
utilizing, for example, a ModBus link 52, through either the
thermostat 30, or through a separate network
controller/coordinator, which may provide for an interface or
gateway with a ModBus link for communicating between the various
component controllers and a ModBus network at an outside location.
An example of such a network controller is a RZ 100E RS-485
peer-to-peer network controller sold by Richards Zeta Corporation.
The network controller/coordinator can send and receive information
to and from the various controllers via the network, and may
include a transceiver for wireless communication of information to
a hand held palm or laptop.
[0020] Where the thermostat 30 is in communication with an external
ModBus link 52, the thermostat 30 may transmit specific parameter
or diagnostic information relating to the individual controllers
and system components to an outside location 50 such as a
monitoring service provider. The outside location 50 could also
send commands to the thermostat 30 to control the operation of the
climate control system or to request specific operating parameter
information. The thermostat 30 could accordingly function as a
gateway for communicating with an outside location 50, and could be
remotely controlled by the outside location 50.
[0021] One first embodiment of an interactive controller 24 is
shown in FIG. 3. The interactive outdoor air conditioning
compressor unit controller 24 may include a processor 60 and a
plurality of switching means 62, 64 for controlling the switching
of line voltage 66, 68 to the compressor motor 42 and the condenser
fan motor. The switching means may include relays such as an
A22500P2 relay manufactured by American Zettler. The condenser fan
motor relay 62 and at least one compressor motor relay 64 are also
in connection with the processor 60. The processor 60 may be a 28
pin PIC16F microprocessor manufactured by Microchip. Relays 62 and
64 have first and second contacts, at least one of which may be in
communication with the processor 60, and preferably at least the
non-moving contact of which is in communication with the processor.
The processor 60 is able to activate the relay and sense voltage at
the stationary contact to verify when the contacts are closed and
open. Thus, the processor 60 has the capability of determining when
the relay contacts have stuck closed when the processor has
requested the relay to be switched to an open position.
[0022] The outdoor unit controller 24 can include a low voltage
power supply that may be a half wave regulated power supply (not
shown) comprising a diode in series with a transistor and a
regulating capacitor and zener diode for gating the transistor. The
power supply may also be a small transformer and zener diode
circuit. The low voltage power supply powers the processor 60,
which includes a plurality of Analog to Digital data inputs for
receiving information from various data inputs in connection with
the outdoor unit controller 24. One particular outdoor condenser
unit controller 24 that may be used in the present disclosure is
the 49H22 Unitary Control manufactured by White-Rodgers, a Division
of Emerson Electric Co.
[0023] The outdoor unit controller 24 also receives input from a
plurality of sensors 72 through 90 for monitoring operating
parameters of the outdoor unit components. These sensors may
include current sensors 72, 74 and 76 for sensing the current level
in the start winding and run winding of the compressor motor 42,
and a sensor 78 for sensing the current in the condenser fan motor
40. Other sensors may include a sensor 80 for sensing the magnitude
of the line voltage to the motors, a temperature sensor 82 for
sensing the condenser coil temperature, a temperature sensor 84 for
sensing the outside ambient temperature, and a temperature sensor
86 for sensing the compressor's refrigerant Discharge Line
Temperature (DLT). The compressor of the outdoor unit 22 may be a
scroll compressor, and may be, for example, a two-step scroll
compressor manufactured by Copeland Corporation. This scroll
compressor includes a high capacity operating level and a solenoid
92 for actuating a mid-capacity operating level. The outdoor unit
controller 24 controls a switch 94 for actuating the mid-capacity
solenoid 92 of the compressor. The outdoor unit controller 24 is
configured to provide diagnostic information or codes based on the
current values obtained from the current sensors 72, 74 and 78 for
monitoring the current in the condenser fan motor 40 and the
compressor motor 42. This current sensing may provide diagnostic
information or fault codes such as a repeated motor protector trip
fault, welded contacts in the switching relays 62 and 64, an open
start winding circuit, an open run winding circuit, or a locked
rotor current fault. The outdoor unit controller may communicate
these failures through a com-port 58 to the network connection 48,
and/or may communicate the failures locally through a flashing
multi-color status LED 56. Examples of the diagnostic information
or fault codes relating to the compressor or condenser fan that may
be communicated are shown in the table below.
TABLE-US-00001 TABLE 1 TABLE 1 EXAMPLE FAULT CODES FOR AN OUTDOOR
COMPRESSOR AND CONDENSER FAN UNIT Status LED Status LED Description
Status LED Troubleshooting Information Green Module Has Power
Supply voltage is present at module terminals "POWER" Red "TRIP"
Thermostat demand 1. Compressor protector is open signal Y1 is
present, Check for high head pressure but the compressor is Check
compressor supply voltage not running 2. Outdoor unit power
disconnect is open 3. Compressor circuit breaker or fuse(s) is open
4. Broken wire or connector is not making contact 5. Low pressure
switch open if present in system 6. Compressor contact has failed
open Yellow Long Run Time 1. Low refrigerant charge "ALERT"
Compressor is running 2. Evaporator blower is not running Flash
Code 1 extremely long run Check blower relay coil and contacts
cycles Check blower motor capacitor Check blower motor for failure
or blockage Check evaporator blower wiring and connectors Check
indoor blower control board Check thermostat wiring for open
circuit 3. Evaporator coil is frozen Check for low suction pressure
Check for excessively low thermostat setting Check evaporator
airflow (coil blockages or return air filter) Check ductwork or
registers for blockage 4. Faulty metering device Check TXV bulb
installation (size, location, contact) 5. Condenser coil is dirty
6. Liquid line restriction (Filter drier blocked if present in
system) 7. Thermostat is malfunctioning Check thermostat sub-base
or wiring for short circuit Check thermostat installation
(location, level) Yellow System Pressure Trip 1. High head pressure
"ALERT" Discharge or suction Check high pressure switch if present
in system Flash Code 2 pressure out of limits Check if system is
overcharged with refrigerant or compressor overloaded Check for
non-condensable in system 2. Condenser coil poor air circulation
(dirty, blocked, damaged) 3. Condenser fan is not running 4. Return
air duct has substantial leakage 5. If low pressure switch present
in system, refer to Flash Code 1 Yellow Short Cycling Compressor 1.
Thermostat demand signal is intermittent "ALERT" is running only
briefly 2. Time delay relay or control board defective Flash Code 3
3. If high pressure switch is present, refer to Flash Code 2 4. If
low pressure switch present, refer to Flash Code 1 Yellow Locked
Rotor 1. Run capacitor has failed. "ALERT" 2. Low line voltage
(contact utility Flash Code 4 if voltage at disconnect is low) 3.
Excessive liquid refrigerant in compressor 4. Compressor bearings
are seized Yellow Measure compressor oil level "ALERT" Open Circuit
1. Outdoor unit power disconnect is open Flash Code 5 2. Compressor
circuit breaker or fuse(s) is open 3. Compressor contactor has
failed open Check compressor contactor wiring and connectors Check
for compressor contactor failure (burned, pitted, or open) Check
wiring and connectors between supply and compressor Check for low
pilot voltage at compressor contactor coil 4. High pressure switch
is open and requires manual reset. 5. Open circuit in compressor
supply wiring or connections 6. Unusually long compressor protector
reset time due to extreme ambient temperature 7. Compressor
windings are damaged Check compressor motor winding resistance
Yellow Open Start Circuit 1. Run capacitor has failed. "ALERT"
Current only in run 2. Open circuit in compressor start wiring or
Flash Code 6 circuit connections Check wiring and connectors
between supply and the compressor "S" terminal 3. Compressor start
winding is damaged Check compressor motor winding resistance Yellow
Open Run Circuit 1. Open circuit in compressor run wiring or
"ALERT" Current only in start connections Flash Code 7 circuit
Check wiring and connectors between supply and the compressor "R"
terminal 2. Compressor run winding is damaged Yellow Welded
Contactor 1. Compressor contactor has failed closed "ALERT"
Compressor always runs 2. Thermostat demand signal not connected to
Flash Code 8 module. Yellow Low Voltage 1. Control circuit
transformer is overloaded "ALERT" Control Circuit <17VAC 2. Low
line voltage (contact utility if voltage Flash Code 9 at disconnect
is low) Check wiring connections
[0024] In one situation, the outdoor unit controller 24 may respond
to sensing an open circuit or locked rotor condition in the
condenser fan motor 40 by discontinuing operation of the compressor
motor 42 and communicating via the network 48 a condenser fan motor
failure to the other controllers 28, 30 and 38 in the HVAC system.
The indoor blower controller 28 and blower motor controller 38
could respond by discontinuing operation until the fault condition
is removed, regardless of whether the thermostat 30 may be calling
for cooling operation. The outdoor unit controller 24 may also
respond to sensing an open circuit or locked rotor condition of the
compressor motor 42 by discontinuing operation of the condenser fan
motor 40 and communicating via the network 48 a compressor motor
failure to the other controllers 28, 30 and 38 in the HVAC system.
The processor 60 of the outdoor unit controller 24 may also control
the speed of the condenser fan motor 40, where a variable speed
motor is utilized, based on the sensed ambient temperature data
received from the temperature sensor 84. When the thermostat 30 is
calling for cooling operation and the sensed outside ambient
temperature is relatively low, as in an overnight or early morning
situation, the outdoor unit controller 24 may responsively operate
the condenser fan motor 40 at a reduced speed for reducing the
operating noise level of the outside unit 22.
[0025] Likewise, in the situation where the thermostat 30 is
calling for cooling and the outdoor unit controller 24 receives a
communication via the network connection 48 of an indoor blower
motor failure, the outdoor unit controller 24 will respond by
discontinuing the operation of the outdoor unit components to
protect the compressor motor 42 from possible damage. Similarly, in
the situation where the thermostat 30 is calling for high capacity
"Y2" second stage cooling, the outdoor unit controller 24 may
receive a communication via the network connection 48 of a reduced
speed for the indoor blower motor 36 due to overheating of the
inverter drive circuit 96 in the blower motor controller 38. The
outdoor unit controller 24 will respond by switching relay 94 for
actuating the mid-capacity solenoid 92 to operate the compressor 42
at a reduced capacity to correspond to the reduced blower motor
speed, regardless of whether the thermostat 30 is calling for high
capacity "Y2" second stage cooling. This provides for a limp-along
mode that will still provide some degree of cooling, while running
the compressor 42 at a capacity corresponding to the reduced speed
of the indoor blower motor 36 to provide safe operation for the
compressor 42.
[0026] In a situation where the thermostat 30 is calling for full
capacity "Y2" second stage cooling and the line voltage 66, 68 to
the compressor motor 42 is sensed to be significantly below rated
operating voltage of the compressor motor 42, the outdoor
controller 24 may discontinue compressor operation at full
capacity, and switch the relay 94 for actuating the mid-capacity
solenoid 92 to operate the compressor 42 at the mid-capacity level.
The outdoor unit controller 24 may then communicate a high capacity
compressor lockout fault via the network 48 to the indoor unit
controller 28, which would responsively request the blower motor
controller 38 to operate the blower motor 36 at the reduced speed
corresponding to "Y1" first stage operation, regardless of whether
the thermostat 30 is calling for "Y2" second stage cooling. If the
thermostat 30 is connected to the communication network 48, the
thermostat 30 may respond to the high capacity compressor lock-out
fault by only calling for low capacity "Y2" second stage cooling,
and by notifying the occupant or an outside location 50 of the low
line voltage and high capacity compressor lock-out fault.
[0027] The outdoor unit controller 24 may also provide a high side
pressure fault, which may be sensed by either a pressure sensor 88
or by the sensed compressor motor current at 72, 74 and 76. For
example, in the Copeland scroll compressor, the sensed motor
current is approximately linear with respect to the sensed high
side refrigerant pressure, and is also an indirect way of measuring
the compressor's high side pressure. In the situation where the
compressor's high side pressure is excessive, the outdoor unit
controller 24 may respond by switching the relay 94 for actuating
the mid-capacity solenoid 92 of the scroll compressor to operate
the compressor 42 at a mid-capacity level. The outside unit
controller 24 may then communicate a high side pressure fault
condition via the network 48 to the other system controllers 28,
30, and 38. The indoor blower controller 28 may then respond by
requesting the blower motor controller 38 to operate the blower
motor 36 at the reduced speed corresponding to "Y1" first stage
operation, regardless of whether the thermostat 30 is calling for
"Y2" second stage cooling. If the thermostat 30 is connected to the
communication network 48, the thermostat 30 may respond to the high
capacity compressor lock-out fault by only calling for low capacity
"Y2" second stage cooling. The thermostat 30 may also notify the
occupant or an outside location 50 of the low line voltage and high
capacity compressor lock-out fault. This provides a limp along mode
of operation at less than full capacity that will still provide
some degree of cooling.
[0028] In the above situation of a compressor high side pressure
fault, the outdoor unit controller 24 may also provide another limp
along mode of operation that limits full capacity compressor
operation to a minimum time duration by cycling the compressor on
and off. This would still provide some degree of cooling without
damaging the compressor 42.
[0029] In the situation where the thermostat 30 is calling for low
capacity "Y1" first stage cooling, and the outdoor unit controller
24 senses via the current level that the mid-capacity solenoid 92
of the scroll compressor is not functioning, the outside unit
controller 24 will switch the compressor to full capacity operation
and communicate a low capacity compressor lock-out fault via the
network 48 to the indoor blower controller 28. The indoor blower
controller 28 may respond by requesting the blower motor controller
38 to operate the blower motor 36 at full speed to correspond with
the full capacity compressor operation, regardless of whether the
thermostat 30 is calling for low capacity "Y1" first stage cooling.
The outdoor and indoor unit controllers 24 and 28 would continue to
operate in only high capacity mode until the low-capacity
compressor lock-out fault signal is removed.
[0030] Where the outdoor unit controller 24 is used in a heat pump
application, the outdoor unit controller 24 may also monitor
current of the compressor motor 42 and the outdoor coil temperature
to control defrost operation of the compressor. Specifically, an
outdoor coil temperature may provide an indication that frost is
building up on the condenser coil. The outdoor unit controller 24
can also sense frost build up by monitoring the current in the
compressor motor 42, which steadily decreases as the load is
hampered by the buildup of frost on the condenser coil. When the
compressor motor current decreases by a predetermined amount, the
outdoor unit controller 24 can ascertain when to initiate a defrost
cycle, in conjunction with or without the temperature value of the
outdoor coil. However, a condenser coil temperature sensor is not
able to detect the presence of frost across the entire outdoor
condenser coil, which may include multiple flow circuits. If any
portion of the coil still has residual frost, the single coil
temperature sensor may not be able to detect the presence of
residual frost. When frost has accumulated across the entire
outdoor condenser coil, airflow becomes restricted and the current
of the condenser fan motor 40 increases as a result of the
restriction. Thus, the current of the condenser fan motor 40 may be
a better predictor for defrost cycle control, and may be monitored
to determine when to either initiate or terminate a defrost cycle.
The current of the compressor motor 42 will increase quickly during
defrost of the condenser coil, and may also be used in conjunction
with the current of the condenser fan motor 40 to determine when to
either initiate or terminate a defrost cycle.
[0031] In yet another situation, the outdoor unit controller 24 may
also monitor the compressor motor current at 72, 74, and 76, and
the discharge line temperature (DLT) to determine if a low
refrigerant charge condition is present. If the outdoor unit
controller 24 senses a high relative compressor motor current and a
high relative DLT rise immediately after starting the compressor
motor 42, the outdoor unit controller 24 would communicate a
possible low refrigerant charge condition via the network 48 to the
other system controllers 28, 30 and 38.
[0032] The processor 60 of the outdoor unit controller 24 may
further be adapted to continuously obtain the sensed line voltage
66, 68 and the sensed current levels at 72, 74, and 78 of the
compressor motor 42 and condenser fan motor 40 during the operation
of these components. By obtaining this data from the line voltage
and motor current sensors, the processor 60 of the outdoor unit
controller 24 can compute the apparent power during the run time of
the outdoor unit 22, and maintain a running KVA total of the power
consumed by the outdoor unit 22. This information may be
periodically communicated via the network 48 to other controllers
in the system such as a thermostat 30 connected to the network 48.
The thermostat 30 could accordingly report the month-to-date
estimated energy consumed, or utility costs, to the occupant or
user of the thermostat 30. The processor 60 of the outdoor unit
controller 24 may also periodically communicate the outside ambient
temperature sensed at 84 via the network 48 to other controllers
such as the thermostat 30, for example. The thermostat 30 could
accordingly adjust its temperature set point based on the ambient
temperature sensed at 84 to improve the economic operation of the
HVAC system.
[0033] In a second embodiment of an interactive controller, an
indoor air handler/circulator blower controller 28 is provided that
includes a processor 100 and at least one output signal 102 which
will request the blower motor controller 38 to operate at a low
speed corresponding to "Y1" first stage cooling operation or at a
high speed corresponding to "Y2" second stage cooling operation.
The indoor air handler/blower controller 28 includes a low voltage
power supply that may be a half wave regulated power supply (not
shown) comprising a diode in series with a transistor and a
regulating capacitor and zener diode for gating the transistor. The
power supply may also be a small transformer and zener diode
circuit. The low voltage power supply powers the processor 100,
which includes a plurality of Analog to Digital data inputs for
receiving information from various data inputs in connection with
the indoor blower controller 28. An example of such an indoor
blower controller 28 is a 49B Series Control manufactured by
White-Rodgers, a Division of Emerson Electric Co.
[0034] The indoor air handler/blower controller 28 may either
receive a call for cool from a thermostat 30 via a conventional 24
volt "Y1" first stage cooling signal or a full capacity "Y2" second
stage cooling signal, or may alternately receive a first or second
stage cooling signal via the network where thermostat 30 is
connected to the network 48. When receiving a request for low
capacity first stage cooling from the thermostat 30, the processor
100 of the indoor air handler/blower controller 28 communicates a
pulsed-width-modulating signal via 108 requesting low speed
operation to a variable speed blower motor controller 38. The
processor 110 of the indoor air handler/blower motor controller 38
receives the signal and responsively controls an inverter driver
circuit 96 to establish low speed operation of the blower motor 36.
When receiving a request for low capacity "Y1" first stage cooling
from the thermostat 30, the indoor air handler/blower controller 28
communicates a high speed signal via 108 to the processor 110 of
the blower motor controller 38. The processor 100 of the indoor air
handler/blower controller 28 may also receive information input
from a return air temperature sensor and a supply air temperature
sensor or from temperature sensors across the evaporator or A-coil.
If the blower motor controller 38 communicates a blower motor
failure via the network 48, the indoor blower controller 28 and
outdoor unit controller 24 will respond by discontinuing the
operation to protect the compressor and or other components from
possible damage. Similarly, in the situation where the thermostat
30 is calling for high capacity "Y2" second stage cooling and the
blower motor controller 38 communicates a high speed blower motor
fault due to an overheated inverter 96, the indoor air
handler/blower controller 28 will request the blower motor
controller 38 to switch the blower motor 36 to low speed blower
operation and communicate a high speed motor blower fault via the
network 48 to the outdoor unit controller 24. The outdoor unit
controller 24 will respond by switching the relay 94 for actuating
the mid-capacity solenoid 92 to operate the compressor 42 at a
reduced capacity to correspond to the reduced speed of the indoor
blower motor 36, regardless of whether the thermostat 30 is calling
to high capacity "Y2" second stage cooling. This provides for a
limp-along mode that will still provide some degree of cooling,
while running the compressor 42 at a capacity corresponding to the
indoor blower motor 36 to provide safe operation for the compressor
42. The indoor air handler/blower controller 28 and the outdoor
unit controller 24 may also communicate to each other information
that may be used to verify whether a condition with the outdoor
unit 22 and a condition with the indoor blower unit 26 confirm a
diagnostic problem in the HVAC system. For example, upon receiving
a communication from the outdoor unit controller 24 of a possible
loss of charge fault, the indoor air handler/blower controller 28
will determine the sensed temperatures across the A-coil and
compare the temperature difference to a predetermined delta to
evaluate whether the difference is out of range. If the temperature
difference across the A-coil is below the predetermined delta, the
indoor air handler/blower controller 28 may communicate the out of
range temperature across the A-coil via the network 48, which would
confirm that the refrigerant charge is low. This information
communicated via the network 48 may be received by a thermostat 30
connected to the network 48, which could then notify the occupant
or an outside location 50 of the low refrigerant charge
condition.
[0035] In the second embodiment of an interactive controller, an
indoor air handler/blower motor controller 38 comprising a
processor 110 and an inverter driver 96 for a variable speed blower
motor 36 is provided. The blower motor controller 38 may receive a
request from either an indoor air handler/blower controller 28 or a
furnace controller 34 to establish any desired speed of the blower
motor 36, within a predetermined operating range. The blower motor
controller 38 includes a low voltage power supply that may be a
half wave regulated power supply (not shown) comprising a diode in
series with a transistor and a regulating capacitor and zener diode
for gating the transistor. The power supply may also be a small
transformer and zener diode circuit. The low voltage power supply
powers the processor 110, which includes a plurality of Analog to
Digital data inputs for receiving information from various data
inputs in connection with the blower motor controller 38.
[0036] The blower motor controller 38 further includes sensors for
sensing the voltage to the inverter driver circuit 96, the motor
speed, and the temperature of the inverter drive circuit 96. The
blower motor controller 38 may include a power module in connection
with line voltage that generates 170 volts DC for the inverter
driver 96, which provides three sine wave outputs to the blower
motor 36. The blower motor controller 38 is capable of sensing an
over-temperature condition in the blower motor 36 or the inverter
96, and responsively reducing the speed of the blower motor 36 to
protect the blower motor windings. The blower motor controller 38
then communicates a reduced speed due to an overheating condition
to the other system controllers via the network 48. The indoor
blower will respond to this communication by requesting the blower
motor controller 38 to switch the motor to low speed blower
operation, and communicate a high speed motor blower fault via the
network 48 to the outdoor unit controller 24. The outdoor unit
controller 24 will respond by switching the relay 94 for actuating
the mid-capacity solenoid 92 to operate the compressor at a reduced
capacity to correspond to the reduced speed of the indoor blower
motor 36, regardless of whether the thermostat 30 is calling for
high capacity "Y2" second stage cooling. This provides for a
limp-along mode that will still provide some degree of cooling,
while running the compressor at a capacity corresponding to the
indoor blower to provide safe operation for the compressor 42.
[0037] Where the blower motor controller 38 experiences an
overheating condition and responsively reduces the blower motor
speed during a call for high stage heating, the blower motor
controller 38 communicates the reduced blower speed condition via
the network 48 to the furnace controller 34. The furnace controller
34 responds to this communication by responsively switching the
operation of the furnace from high stage "W1" operation to low
stage "W2" operation, regardless of whether the thermostat 30 is
calling for "W1" high stage heating. The furnace controller 34 in
this example embodiment includes a processor 124 for controlling
the switching of line voltage to the igniter 118, the switching of
low voltage to a gas valve relay 120, and low voltage to a second
stage gas valve relay 122. In the event the blower motor controller
38 communicates a reduced blower motor speed, the furnace
controller 34 will request the blower motor controller 38 to
establish the low speed blower motor operation corresponding to the
"W2" low heating stage, and communicate a lock-out of high stage
heating via the network 48 to the thermostat 30. If the thermostat
30 is connected to the communication network 48, the thermostat 30
may respond to the high stage heating lock-out communicated by the
furnace controller 34 by only calling for low stage heating "W1",
and by notifying the occupant or an outside location 50 of the high
speed blower motor fault. The blower motor controller 38 may also
communicate the line voltage value at 114 via the network 48 to the
furnace controller 34 for a fuel-fired furnace, which may use the
line voltage value at 114 in determining a routine for switching
line voltage at 116 to a hot surface igniter 118 for igniting gas,
for more accurately controlling the power level to the hot surface
igniter. This communication of line voltage information to the
furnace controller 34 for a fuel fired furnace improves the life of
the hot surface igniter.
[0038] In the second embodiment in accordance with the present
disclosure, the indoor air handler/blower controller 28 includes a
processor 100 for controlling at least one switching relay 102 for
controlling the selection of a plurality of operating speeds of the
indoor blower motor 36. The indoor blower controller 28 may either
receive a call for cool from a thermostat 30 via a conventional 24
volt "Y1" first stage cooling signal or a full capacity "Y2" second
stage cooling signal, or may alternately receive a first or second
stage cooling signals via the network 48 where thermostat 30 is
connected to the network. The processor 100 of the indoor blower
controller 28 may also receive sensed return air temperature and
supply air temperature from temperature sensors 104 and 106 across
the A-coil and/or heat exchanger. The processor 100 of the indoor
blower controller 28 may also receive the sensed temperatures at
the inlet and outlet of the a-coil. In one embodiment of the
present disclosure, the indoor blower controller 28 may be
configured for use with a multi-speed blower motor 36 that is
directly switched via at least one relay 102 by the indoor blower
controller 28. The indoor blower controller 28 is capable of
determining a malfunction in either the high speed operation or low
speed operation of the motor corresponding to the first and second
stage operation of the compressor. In the event that a malfunction
occurs in the high speed operation or low speed operation, or both,
the indoor blower controller 28 communicates the malfunction via
the network 48 to the other system controllers 24, 30, 34 and 38.
If the indoor blower controller 28 communicates a complete blower
motor failure, the outdoor unit controller 24 will respond by
discontinuing the operation of the outdoor unit 22 to protect the
compressor from possible damage. Similarly, in the situation where
the thermostat 30 is calling for high capacity "Y2" second stage
cooling and the indoor unit senses a high speed blower motor
failure, the indoor blower will switch the blower motor 36 to low
speed blower operation and communicate a high speed motor blower
fault via the network 48 to the outdoor unit controller 24. The
outdoor unit controller 24 will respond by switching the relay 94
for actuating the mid-capacity solenoid 92 to operate the
compressor at a reduced capacity to correspond to the reduced
indoor blower motor speed, regardless of whether the thermostat 30
is calling to high capacity "Y2" second stage cooling. This
provides for a limp-along mode that will still provide some degree
of cooling, while running the compressor at a capacity
corresponding to the reduced speed of the indoor blower motor 36 to
provide safe operation for the compressor. If the thermostat 30 is
connected to the communication network 48, the thermostat 30 may
respond to the high speed blower motor fault communicated by the
indoor blower controller 28 by only calling for low capacity "Y2"
second stage cooling, and by notifying the occupant or an outside
location 50 of the high speed blower motor fault. The indoor blower
controller 28 and the outdoor unit controller 24 may also
communicate to each other information that may verify whether a
condition with the outdoor unit 22 and a condition with the indoor
blower 26 confirm a diagnostic problem in the HVAC system. For
example, upon receiving a communication from the outdoor unit
controller 24 of a possible loss of charge fault, the indoor blower
controller 28 will determine the sensed temperatures across the
A-coil and compare the temperature difference to a predetermined
delta to evaluate whether the difference is out of range. If the
temperature difference across the A-coil is below the predetermined
delta, the indoor blower controller 28 may communicate the out of
range temperature across the A-coil via the network 48, which would
confirm that the refrigerant charge is low. This information
communicated via the network 48 may be received by a thermostat 30
connected to the network 48, which could then notify the occupant
or an outside location 50 of the low refrigerant charge
condition.
[0039] In the various embodiments of interactive controllers, each
of the various controllers 24, 28, 30, 34 and 38 also initially
establish a base value for various operating parameters relating to
each of the controllers and corresponding components. For example,
the blower motor controller 38 may establish a base value for the
line voltage and speed of the blower motor 36, and calculate a base
Cubic Feet per Minute (CFM) of the blower motor 36. When a
predetermined reduction in calculated CFM occurs (indicating a
dirty air filter), the blower motor controller 38 may communicate a
dirty or clogged air filter condition via the network 48 to the
thermostat 30, which may responsively notify the occupant or an
outside location 50 of the dirty filter condition. In another
situation, a baseline curve of the compressor discharge pressure
versus the compressor motor current relative to the ambient
temperature could be obtained. Any subsequent variation from the
curve relationship between the discharge pressure and compressor
motor current values could be used to indicate a fault or to
predict degradation and potential failure of the compressor.
Likewise, the outdoor unit controller 24 may establish a base value
for the DLT 86 and the sensed current at 72, 74 and 76 for the
compressor motor 42 relative to the sensed outside ambient
temperature at 84. When the DLT at 86 and the compressor motor
current rise significantly above the relative base line values, the
outside controller 24 responsively communicates a possible low
charge condition via the network 48 to the thermostat 30. The
thermostat 30 may then notify the occupant or an outside location
50 of the possible low charge condition.
[0040] In one embodiment of an interactive system for controlling a
climate control system, an interactive thermostat controller 30 may
be connected to the network 48 and is capable of receiving
diagnostic and fault information communicated from the various
controllers 24, 28, 24 and 38 in the HVAC system. It should be
noted, however, that the interactive system is also capable of
operating with conventional thermostats that are not capable of
being connected to the network 48. The thermostat 30 may include an
initial set-up mode that will prompt scheduled operation periods of
all of the various controllers and components upon installation, to
speed the process of obtaining base line parameter information for
the various controllers and components within the system. For
example, the thermostat 30 could detect the installation or
connection of a compressor via the network 48, and enter a learn
mode that initiates scheduled operation of the compressor during
the day and night, to quickly obtain a baseline curve of the motor
current relative to outside ambient temperature. The thermostat 30
of the present example embodiment may be controlled by a processor
128 and is connected to the peer-to-peer network 48 via an RS 485
connection for communicating to the other system controllers 24,
28, 34 and 38 in the HVAC system. The thermostat 30 may further
include a wireless transmitter and receiver, for receiving
transmitted temperature information from a plurality of temperature
sensors 54 for a plurality of zones within the space. The
thermostat 30 may further include a communication board (not shown)
in the sub-base of the thermostat 30 that is adapted to provide a
gateway connection to an external ModBus communication link 52. The
thermostat 30 may receive requests through the ModBus network at an
external location 50 to transmit specific parameter information,
upon which the thermostat 30 may prompt the various controllers to
obtain parameter information for communication to the external
location 50. This parameter information can be monitored by an
operation monitoring service provider that may predict the possible
failure of various components in the system based on degradation in
parameter values. One example of an outside monitoring service
provider that utilizes a ModBus network is the Emerson Retail
Services group which similarly monitors the operation of commercial
refrigerator cases.
[0041] The thermostat 30 may be configured to receive diagnostic
information or fault signals communicated via the network 48, and
to display the diagnostic information or fault signal on a display
means to alert the occupant. This fault signal may be an icon that
flashes, for example, synchronously with the signal received from
the network 48. The thermostat 30 may also be configured to respond
to a fault signal with a standard message such as "FAULT" or "NEEDS
SERVICE" that flashes, for example, synchronously with the signal
received from the network 48. The fault signal may also be an error
code or text message specific to the indoor blower controller 28 or
the outdoor unit controller 24. An example of a parameter that may
be monitored is the flame signal obtained from a flame probe within
a fuel-fired furnace, which the furnace controller 34 could
communicate via the network 48 through the thermostat 30. The
service provider would then be able to service the flame probe
sensor before the furnace controller 38 shuts down the furnace
operation.
[0042] Another example of parameters the thermostat 30 may monitor
include the rate of temperature change in each of the zones within
the space, which may be compared to an initial baseline rate of
temperature change. Over time, the cooling system may experience a
gradual reduction in capacity that results in a reduced rate of
temperature change for the space. The thermostat 30 may accordingly
sense when the rate of temperature change decreases below a
predetermined optimum baseline rate of temperature change. The
thermostat 30 may compare this data with data received from the
outdoor unit controller 24 concerning high motor current and high
discharge line temperature indicative of a possible low refrigerant
charge. Likewise, the thermostat 30 may also obtain data from the
indoor blower unit controller 28 concerning a below normal
temperature delta across the A-coil indicating a low refrigerant
charge. This comparison of data at various communication nodes
provides confirming diagnostics that strengthen predictions of
system maintenance and diagnosis. The above situation of a low
refrigerant charge could provide notification to a home owner of an
inefficiency that often is unnoticed and overlooked. The thermostat
30 could provide notice to the homeowner, who could then service
the system and reduce energy costs.
[0043] Some embodiments of an interactive HVAC system may further
include a plurality of zone dampers 56 for controlling the supply
of conditioned air to the one or more zones within the space.
Either the thermostat 30, or a damper controller, are capable of
opening or closing individual zone dampers 56 in response to the
temperature sensed by the remote temperature sensors 54 in each
zone, to provide conditioned air from the indoor air blower 36 to
each zone requiring heating or cooling. The plurality of zone
dampers 56 may also be connected to the network 48. In response to
a signal from the outdoor unit controller 24 via the network 48 of
a reduced capacity operation malfunction (resulting in full
capacity operation of the compressor 42 and indoor blower motor
36), the thermostat 30 responsively would communicate a request
signal to open each zone damper to correspond to a full capacity
operation mode. Likewise, in response to a signal from the outdoor
unit controller 24 via the network 48 of a full capacity operation
malfunction (resulting in reduced capacity operation of the
compressor 42 and indoor blower motor 36), the thermostat 30
responsively would communicate a request signal to open only a
minimum number of dampers to correspond to the reduced capacity
operation mode.
[0044] In addition to the above thermostat 30, or where the
interactive system operates with a conventional thermostat that is
not connected to the network 48, a separate interface controller
(not shown) may be connected to the network 48 for providing
communication between the various controllers and a user or outside
location 50. The separate interface controller would be capable of
providing the same gateway connection to an external ModBus
communication link as in the afore described thermostat embodiment,
and may also include an interface and display means for user access
of system information. The interface controller therefore would
allow a user or service technician to obtain diagnostic information
and operating parameters relating to the HVAC system components,
and would also provide for communication of diagnostic information
to an outside location 50 such as a monitoring service provider.
The interface controller would be able to receive information from
the various indoor and outdoor unit controllers to provide
confirming diagnostics for predicting potential component failure
or required servicing, and communicate such information to the
user, service technician, or an outside party.
[0045] Thus, various embodiments of an interactive system for
controlling a plurality of HVAC components may include one or more
controllers for controlling one or more components of the HVAC
system. Some embodiments include at least one controller for
operating a component of the HVAC system, where the controller is
capable of modifying the operation of the component in response to
information received about the operation of at least one component
of the HVAC system. It should be noted that the information
pertaining to the operation of at least one component of the HVAC
system may include temperature information from a remote
temperature sensor component that is connected to the network. The
information pertaining to the operation of at least one component
may include sensed carbon monoxide level information from a carbon
monoxide sensor component that is connected to the network. The
information pertaining to the operation of at least one component
may also include sensed discharge line temperature (refrigerant
temperature at the compressor) that is detected and communicated by
an interactive controller for an outdoor air conditioning
compressor unit. Accordingly, the interactive controllers may
modify the operation of at least one component under their control
in response to monitoring various types of information pertaining
to the operation of a sensor, component, or another interactive
controller. The table below illustrates how various embodiments of
an interactive system can include a combination of controllers,
which controllers control certain components (indicated by C) and
may modify the operation of its respective components in response
to information received about the operation of other components
(indicated by I) of the HVAC system.
TABLE-US-00002 TABLE 2 ModBus Zone network Compressor Condenser fan
Indoor A-coil Blower motor Furnace Zone temperature or Controller
(multi-stage) (multi-speed) Outdoor sensors temperature
(multi-speed) (multi-stage) dampers sensors gateway Outdoor unit C
C I I I I controller Indoor blower I I C I I I controller Blower
motor I I I C I I I controller Furnace X X X X C/I C I I controller
Thermostat C/I C/I I I C/I C/I C/I I I control Damper I C I I
controller
[0046] Some embodiments of an interactive system may also include a
Personal Digital Assistant, PALM, or a computer or hand held device
134 may also be connected to the peer-to-peer network, for
receiving operating information relating to the various controllers
and components in the HVAC system. Such a device could be connected
to the RS-485 network by a service technician during installation
or servicing for troubleshooting and diagnosing the various
components in the HVAC system. The hand held device 134 or computer
could request parameter information and display the values of
various sensors associated with the controllers connected to the
network within the HVAC system, and display the information for the
service technician. Such a device could include a hand held palm,
which could be easily connected and programmed to receive and parse
the information being communicated between the various HVAC
controllers. It should also be noted that some of the components of
the HVAC system may also communicate wirelessly with the network
through the use of a transceiver unit in connection with the
peer-to-peer network.
[0047] In a third embodiment of an interactive controller, an
alternate variation of an interactive controller 24' is provided
for an outdoor air conditioning compressor unit, which includes a
processor 60 and a means for communicating with a compressor
diagnostic unit associated with the compressor. The compressor
diagnostic unit (not shown) includes current sensing means and
voltage sensing means for sensing the level of line voltage as well
as the current in the run windings and the start windings of the
compressor motor 42. The interactive controller 24' of the third
embodiment includes relays (62 or 64) for switching power to the
compressor motor 42, and receives current and voltage information
from the compressor diagnostic unit rather than directly monitoring
the current to the compressor motor 42. The compressor diagnostic
unit passively monitors the current in the compressor motor 42 and
communicates compressor diagnostic information to the interactive
controller 24' for the outdoor unit or directly to the thermostat
30. This third embodiment of an interactive controller 24' can
communicate much of the same diagnostic information and faults as
described in the first embodiment of an interactive controller, to
provide diagnostic information to other components on the network
48 such as the thermostat 30. The interactive controller 24' may
also switch compressor operation from high capacity to the
mid-capacity level, based on information received from the
compressor diagnostic unit. The compressor diagnostic unit may also
communicate compressor operating parameters and diagnostic
information directly to the thermostat 30, which may responsively
control cooling request signals for activating the compressor motor
42 and condenser fan motor 40. The thermostat 30 is therefore
capable of initiating or activating the compressor motor 42 and the
compressor fan motor 40, based on the information received from the
compressor diagnostic unit or the interactive controller 24'. The
thermostat 30 may further request full capacity operation or less
than full capacity operation, based on information communicated by
the compressor diagnostic unit or the interactive controller 24'.
An example of a thermostat 30 that may receive direct communication
from a compressor diagnostic unit is disclosed in U.S. patent
application Ser. No. 10/750,113 entitled "Thermostat for use with
compressor health indicator", which is incorporated herein by
reference. An example of a compressor diagnostic unit that may
sense compressor operating parameters is disclosed in U.S. patent
application Ser. No. 10/625,979 entitled "Compressor Diagnostic
System For Communicating With An Intelligent Device", which is
incorporated herein by reference. The compressor diagnostic unit
may also communicate a high side pressure fault condition, which
may be sensed by either a pressure sensor 88 or by the compressor
motor current. For example, the compressor diagnostic unit may
sense a compressor motor current that may indirectly indicate a
compressor high side refrigerant pressure, and may respond by
communicating this high side pressure fault to either the outdoor
unit controller 24' or the thermostat 30. The thermostat 30 may
respond by subsequently providing a request signal for high
capacity of "Y2" second stage, rather than a request signal for low
capacity operation of "Y1" first stage. The thermostat 30 may
accordingly perform the switching of the compressor operation from
high capacity to the mid-capacity level based on information
received from the compressor diagnostic unit. Thus, this second
embodiment of an outdoor unit controller 24' provides for passive
control of the compressor, through the interactive communication
with a compressor diagnostic unit of various operating parameters
and faults to the thermostat 30 or the interactive controller
24'.
[0048] In another aspect of the present disclosure, various
embodiments of an interactive system are provided that have
interactive controllers configured to monitor or listen to signals
communicated via the two-wire network, which signals are addressed
to or intended for a device other than the controller that is
monitoring or listening to the signal. Some embodiments of an
interactive system further include at least one controller that is
capable of modifying the operation of at least one component that
the at least one controller has control over, in response to
receiving a signal that is intended for another controller which
includes information about the operation of a component within the
climate control system.
[0049] It should be noted that the presently disclosed means for
communicating signals within an HVAC system is a significant
departure from conventional thermostats that include several wires
connected to various HVAC system controls and components. For
example, in a conventional system, heating is activated when the
conventional thermostat switches a 24 volt AC power source to
supply a 24 volt AC signal to a specific individual wire that is
connected to a heating system. Likewise, fan operation is activated
when the conventional thermostat switches a 24 volt AC power source
to supply a 24 volt AC signal to another specific individual wire
that is connected to a blower fan motor or a fan contactor. The
conventional thermostat switches a 24 volt AC signal to a specific
wire for actuating each individual heating, fan or cooling system
component. Accordingly, each wire in connection with a conventional
thermostat is connected to a different HVAC system component. In
heating system or thermostat replacement situations, wiring
installed through the walls to an existing thermostat may not be
color coded or distinguished from each other, and can potentially
be inadvertently confused or interchanged with each other. This can
make installation of a replacement conventional thermostat
difficult, and can lead to inadvertent miswiring of the thermostat
to the wrong HVAC component.
[0050] According to one aspect of the present disclosure, various
embodiments of an interactive system provide for sending digital
signals to an intended destination or address of a specific
controller in the system, where the signals are transmitted across
a two-wire network in connection with various controllers or system
components. The systems in the present disclosure do not require a
specific wire to be connected directly from the thermostat to each
specific HVAC component, such that the thermostat must transmit a
24 volt signal through a specific individual wire associated with a
specific individual HVAC component to activate the HVAC component.
Rather, the present systems use only two-wire "bus" network
transmission lines for sending signals, to eliminate the need for a
dedicated individual wire connecting each specific individual
controller to the thermostat. Thus, the various controllers are
connected to each other only through the two wire network. In the
various embodiments, a thermostat controller 420 may transmit a
signal via the two-wire network that includes information
identifying the intended destination or address of a specific
controller. Where the signal is requesting operation of a specific
individual controller, the signal includes a unique command that is
specific to only the individual controller that the thermostat is
requesting operation of. Thus, the thermostat controller 420 could
send a signal that only requests operation for a specific
controller, unlike the conventional thermostat that sends a 24 volt
AC signal (or half wave rectified 24 volt signal) across an
individual wire, which voltage signal could activate any HVAC
component that the wire is connected to.
[0051] Various embodiments of interactive systems disclosed provide
a means of transmitting digital data signals to components and
controllers, which signals are not capable of activating or
powering an HVAC control or component as would a 24 volt signal (or
half wave rectified 24 volt signal). The transmitted digital
signals are sent across the two wire bus network in connection with
the various HVAC controllers and components rather that via a
specific individual wire used to control activation of an HVAC
system component. Unlike conventional systems, where a 24 volt AC
waveform or a rectified 24 volt AC waveform may be conducted via a
specific individual wire to activate an HVAC control connected to
the individual wire, or where a 24 volt AC waveform that powers a
control may be half wave rectified to both signal activation of the
control and power the control as well, the present means of
communication does not transmit a signal via a specific wire
connected to an individual HVAC control to "activate" the HVAC
control. Rather, the present means transmits a digital signal that
will only request operation of a specific HVAC component, by virtue
of a command that is unique to the specific controller. This
prevents the possibility of tampering that is present in a
conventional system, where an individual wire that transmits a 24
volt AC "activation" signal (or half wave rectified signal) could
be jumpered or connected to an HVAC control or component to operate
the component.
[0052] A significant aspect of the present disclosure is that one
can tailor or create various embodiments of a "networked" HVAC
system, in which a first controller associated with an HVAC
component is installed and connected to a two-wire network, and at
least one other controller associated with another HVAC component
is subsequently or incrementally installed and connected to the
network, to provide at least one controller that is capable of
monitoring signals from and communicating signals to the at least
one other subsequently installed controller for enabling an
interactive system without requiring configuration of the
individual controllers through a master thermostat.
[0053] As an example, a home owner having an existing HVAC system
might decide to replace only their worn-out outdoor
air-conditioning compressor unit with a new outdoor
air-conditioning compressor unit, which includes an interactive
controller according to the present disclosure. The interactive
controller for the air-conditioning compressor unit is initially
connected to a specific wire that transmits a 24 volt request
signal sent by the conventional thermostat, and also to a two-wire
network on which the controller periodically transmits data
signals. Without detecting any signals from other controllers
connected to the network, the interactive controller simply
activates the compressor in response to the 24 volt signal sent by
the existing conventional thermostat. At a later point in time, the
home-owner decides to subsequently replace the old indoor air
handler unit with a new air handler unit including an interactive
controller. The interactive controller associated with the new air
handler is incrementally connected to the network, and is capable
of monitoring signals from and communicating signals to the
interactive controller for the outdoor air-conditioning compressor
unit. Accordingly, each of the two interactive controllers are
subsequently capable of monitoring signals sent by the other, and
also capable of modifying the operation or operating capacity of
their respective units in response to receiving a signal that
includes information about an operating parameter of at least one
HVAC component. The interactive response of the controllers may be
illustrated by the following situation. The conventional thermostat
sends a 24 volt signal to the interactive controller for the
outdoor air conditioner unit, which would responsively activate or
operate the outdoor compressor. The interactive controller for the
outdoor air conditioner unit may responsively send a signal via the
network communicating the activation of the outdoor compressor
(which signal would be addressed to an interactive thermostat that
is not installed). The interactive controller for the air handler
may monitor the signal indicating compressor operation (which is
intended for an interactive thermostat that is not installed), and
responsively operate the indoor air circulator blower regardless of
whether the conventional thermostat sends a 24 signal to the air
handler controller. In this manner, the interactive controller for
the indoor air handler need not be connected to a specific wire
associated with the conventional thermostat, or to a "master-slave"
control thermostat. Thus, unlike master-slave HVAC networks that
first require the installation of a master thermostat for
coordinating communication between subordinate controllers, the
preceding exemplary embodiment allows a home owner to create an
HVAC network by incrementally adding new interactive controllers
one at a time, without having to purchase or install a master
thermostat or to configure the individual controllers. Accordingly,
the preceding exemplary embodiment enables interactive control of
one or more HVAC system components, without requiring a "master"
control thermostat, or having to configure each of the individual
controllers to communicate with or to be controlled by a master
thermostat.
[0054] Furthermore, the preceding exemplary embodiment of an
interactive system provides for intelligent control of the outdoor
air conditioner compressor and indoor air handler units. This may
be illustrated by the situation of an over-temperature condition in
either the compressor motor or the indoor air circulator blower
motor. In the event of an over-temperature condition in the indoor
air circulator blower motor, the interactive controller for the
indoor air handler unit would discontinue circulator blower motor
operation, regardless of whether the conventional thermostat is
sending a 24 volt signal requesting air conditioning operation. The
interactive controller for the indoor air handler unit would
responsively send a signal via the network communicating the
discontinued circulator blower motor operation (which signal would
be addressed to an interactive thermostat that is not installed).
The interactive controller for the outdoor air conditioning
compressor unit may monitor the signal indicating discontinued
circulator blower motor operation (which is intended for an
interactive thermostat that is not installed), and responsively
discontinue operation of the compressor, regardless of whether the
conventional thermostat sends a 24 volt signal to the air handler
controller. In this manner, the interactive controller for the
outdoor compressor unit can protect the compressor from damage as a
result from the indoor coil unit freezing up due to inoperation of
the blower motor. The interactive controller for the indoor air
handler will subsequently re-activate the circulator blower motor
after enough heat is dissipated to remove the over-temperature
condition, and will responsively send a signal via the network
communicating the circulator blower motor operation (which signal
would be addressed to an interactive thermostat that is not
installed). The interactive controller for the outdoor air
conditioning compressor unit may monitor the signal indicating
circulator blower motor operation and responsively establish
operation of the compressor, to provide a limp along mode of air
conditioning until the over-temperature condition is corrected
while protecting the compressor motor from damage. Thus, the
interactive controllers are capable of modifying the operating
capacity of at least one climate control system component in
response to receiving a signal that includes information about an
operating parameter of at least one other component in the climate
control system, without requiring the installation of a
master-slave type thermostat.
[0055] In the preceding exemplary embodiment, a carbon monoxide
detector may also be installed and connected to the network. In the
event that the carbon monoxide detector senses an undesirable level
of carbon monoxide, the sensor may sound an alarm and may be
configured to send a signal via the network (which signal would be
addressed to an interactive thermostat that is not installed). The
interactive controller for the indoor air handler unit is capable
of monitoring the sensor's signal and may be configured to
responsively activate the air circulator blower to help dissipate
the presence of carbon monoxide gas. Accordingly, the interactive
controller for the indoor air handler unit is capable of modifying
the operation of at least one climate control system component in
response to receiving a signal that includes information about an
operating parameter of at least one other component in the climate
control system, without requiring the installation or use of a
master-slave type thermostat or any set-up and configuration of the
network using a master-slave device.
[0056] In a master/slave network system, a single central
controller determines when other sub-devices connected to the
network may transmit. In systems employing a master/slave network,
a network of devices must be configured through the master
controller to assign an address to each of the installed
sub-devices to enable the sub-devices to communicate via the
network. If an HVAC system were to employ a "master" thermostat,
the master thermostat would control when the other sub-controllers
could communicate via the network. Accordingly, sub-controllers
would only communicate information in response to a query or
request from a "master" thermostat, which would serve as the
receiver of all information and initiator of all operational
commands for the various sub-controllers for directly controlling
the operation of each controller. Unlike the "master" thermostat
approach, the various embodiments in the present disclosure include
controllers that are configured to freely transmit signals via the
network to any other controller, independent of any control by a
"master" thermostat or setup of network addresses through a
"master" thermostat. The controllers of the present disclosure are
also capable of monitoring signals addressed to or intended for
other controllers, and responsively modifying the operation of a
component under their control, independent of any control by a
"master" thermostat. Thus, the interactive systems and controllers
of the present application are significantly different from
Server/Client networks used in large commercial buildings to
control HVAC systems, or HVAC systems that utilize a central
"master" thermostat that controls or dictates when sub-controllers
can communicate information or modify operation of an HVAC
component.
[0057] Accordingly, various embodiments of an interactive system
having a first controller and at least one other controller are
provided for enabling interactive communication in a climate
control system, to improve control of climate control system's
operation. In the various embodiments, an interactive system is
provided that includes a two-wire network and at least two
controllers configured to transmit and receive signals via the
two-wire network absent any control by a master controller. Each
controller is capable of listening to signals sent by other
controllers via the network that are addressed to other controllers
and include information about the operation of at least one
component in the climate control system, and responsively modifying
the operation of at least one component of the climate control
system that the controller has control over based on the
information about the operation of at least one component in the
climate control system.
[0058] In the preceding exemplary embodiment, the home owner may
subsequently purchase and install an interactive thermostat
controller, which may be connected to the two-wire network. The
interactive thermostat would be capable of receiving sensed
temperature information from remote sensors to determine when to
request heating or cooling operation. The interactive thermostat
controller would then be capable of communicating signals intended
for specific interactive controllers, which signals may request
operation of a component of a climate control system that the
interactive controllers are associated with. For example, the
interactive controller for the outdoor air conditioning compressor
unit would be capable of receiving a signal via the network from
the interactive thermostat controller, which requests the
interactive controller for the outdoor air conditioner unit to
operate the compressor. Likewise, the interactive controller for
the indoor air handler unit would be capable of receiving a signal
via the network from the interactive thermostat controller, which
requests the interactive controller for the indoor air handler to
operate the air circulator blower motor. In the event that the
interactive controller for the indoor air handler unit discontinues
blower operation and sends a signal via the network addressed to
the interactive thermostat communicating the discontinued
circulator blower motor operation, the interactive thermostat would
be capable of receiving the signal and at least displaying
information pertaining to the discontinued blower operation on a
display device of the thermostat. The interactive controller for
the outdoor air conditioning compressor unit would also monitor the
signal intended for the interactive thermostat indicating
discontinued circulator blower motor operation, and would
responsively discontinue compressor operation as well, independent
of any direct command or control by the thermostat. Thus, the
preceding exemplary system can use a thermostat while allowing
interactive communication between and operational control by each
of the controllers.
[0059] In the various embodiments of interactive controllers, the
interactive controllers may be configured for controlling operation
of various components in a desired manner. For example, an
interactive controller for an outdoor air conditioning compressor
unit may be configured to have a desired lock-out time between
compress stop and start-up, which may be selected from a number of
pre-select time periods. Likewise, an interactive controller for an
outdoor air conditioning compressor unit may be configured to have
a desired number of motor protector trips before locking out
further operation of the compressor (to protect the compressor),
which number may be selected from a number of pre-select time
periods. Similarly, an interactive controller for an indoor air
handler may have a selectable time delay period for delaying the
shut-off of the indoor blower motor after the furnace's burner has
stopped, to continue to remove any latent heat from the furnace.
The interactive controller for an indoor air handler may be
configured to have a desired time delay period, which may be
selected from a number of pre-select time periods. Thus, each of
the interactive controllers may be configured to select or include
certain desired operating features. Each of the controllers may be
individually configured by an installer. Alternatively, an
installer may utilize a thermostat controller described in the
preceding exemplary embodiment, to communicate configuration data
via the network through the thermostat to a particular controller.
In this manner, the installer may remotely configure desired
settings or options that may be selected on the controller for the
outdoor air conditioning compressor unit, or on the controller for
the indoor air handler unit, without having to go to the location
of each of the individual controllers. Thus, while a thermostat
controller is not necessary for set up of other controllers and
does not control communication by the other controllers, the
thermostat controller may be utilized to configure each of the
controllers via the network.
[0060] A fourth embodiment of a plurality of interactive
controllers that form a system is shown in FIG. 4. The system
includes an integrated furnace controller 442, for controlling the
operation of one or more components of the heating system. The
integrate furnace controller 442 is capable of modifying the
operation of the one or more heating system components it controls,
such as a two-stage gas valve, in response to receiving information
transmitted via the two-wire "bus" network about the operation of
another controller or component within the heating, ventilation,
and air conditioning system. The controller for a circulating air
blower 428 may, for example, include a variable speed circulator
blower motor controller 438 with an inverter driver, which if
overheated would reduce the speed of the circulator blower. The
blower controller could responsively communicate its reduced speed
information by transmitting a signal via the two-wire "bus" network
lines. The signal may be intended for a specific controller, such
as the thermostat controller 420 or the integrated furnace
controller 442. Where the signal is intended for the integrated
furnace controller 442, the integrated furnace controller 442 would
respond to the blower's reduced speed signal by modifying its
operation to that of only low stage heating operation to correspond
to the reduced circulator blower speed. The integrated furnace
controller 442 would operate in low stage heating mode even though
the thermostat controller 420 has requested the integrated furnace
controller 442 to operate the furnace at high stage heating. Where
the signal includes an address or intended destination of a
thermostat controller 420, the integrated furnace controller 442
may still "listen" to the signal intended for the thermostat
controller 420, and responsively restrict operation to low stage
heating. Likewise, where the furnace shuts off after sensing an
over-temperature condition, the furnace controller may signal the
blower controller 428 to continue operating until the
over-temperature condition is alleviated. Accordingly, a single
signal transmission intended for a specific controller that
includes information of an operating condition can improve
operation of multiple controllers. The integrated furnace
controller 442 could, for example, communicate the restriction of
its heating operation to the thermostat controller 420, which would
alert the occupant of a need for service.
[0061] In one aspect of the present disclosure, some embodiments
include one or more interactive controllers for a climate control
system, where at least one controller is capable of modifying the
operation of one or more system components under its control in
response to receiving a signal transmitted by another controller
that includes information about the operation of at least one
component or controller in the climate control system. In the
fourth embodiment, the system may include at least two controllers
for controlling the operation of one or more components of the
cooling system. The at least two controllers 408 and 452 can
communicate via the two-wire "bus" network lines to provide for
operation in either a full capacity mode of operation or a reduced
capacity mode of operation, based on the communication by one of
the at least two controllers of information relating to the
operation or condition of a component under the individual
controller's control. For example, if the thermostat controller 420
transmits a signal requesting compressor operation and the indoor
air handler/circulating air blower controller 452 is not capable of
operating, the indoor air handler controller may detect the blower
operation failure (by a pressure sensor, motor current sensor, or
temperature sensor for example) and transmit a signal via the
two-wire "bus" network lines communicating the failure to another
controller. The signal may be intended for a specific controller,
such as the thermostat controller 420 or the compressor unit
controller 408. Where the signal is intended for the compressor
unit controller 408, the compressor unit controller 408 could
respond to the information of a blower failure by modifying its
operation to shut down the compressor to protect the compressor
motor from possible damage due to the indoor coil unit freezing up.
The compressor unit controller 408 would shut down even though the
thermostat controller 420 is still requesting operation of the
compressor. Where the signal includes an address or intended
destination of a thermostat controller 420, the compressor unit
controller 408 may still "listen" to the signal intended for the
thermostat controller 420, and responsively shut down the
compressor to protect the compressor. The compressor unit
controller 408 could subsequently transmit a signal via the
two-wire "bus" network lines that is addressed to the thermostat
controller 420, for communicating the shut down of the compressor
due to the information on the failed circulator blower, such that
the thermostat controller 420 may alert the occupant of a need for
service.
[0062] In yet another aspect, some embodiments of an interactive
system may include at least two controllers that communicate
information via the two-wire "bus" network lines to provide for
controlling operation of one or more system components in either a
full capacity mode or a reduced capacity mode of operation based on
the communication of information relating to the operation of one
of the at least two controllers. For example, in the fourth
embodiment, the system includes at least two controllers that
together provide for controlling the operation of a multi-stage air
conditioning system in either a high capacity or a low capacity
mode. If a first compressor unit controller is not able to
continuously operate the compressor in high capacity mode (due to a
high discharge line temperature, or high motor current for
example), the compressor unit controller could restrict operation
to low capacity mode and transmit a signal via the two-wire "bus"
network lines communicating the restriction. The signal may be
intended for the second controller 452 for an air handler
circulating air blower, or for the thermostat controller 420. Where
the signal is intended for the circulating air blower controller
452, the circulating air blower controller 452 could receive the
signal and responsively reduce the circulator blower speed to
correspond to the low capacity compressor mode of operation to
allow the air conditioning system to operate in a limp-along mode
until the air conditioning system can be serviced. The compressor
and circulating air blower would be operated at a low capacity mode
even though the thermostat controller 420 is still requesting
operation at high capacity. Where the signal includes an address or
intended destination of a thermostat controller 420, the
circulating air blower controller 452 may still "listen" to the
signal intended for the thermostat controller 420, and responsively
reduce the circulator blower speed to correspond to the low
capacity compressor operation mode.
[0063] In yet another aspect of the present disclosure, some
embodiments of an interactive system may include controllers that
include a microprocessor capable of transmitting one or more unique
data signals through a UART interface. The microprocessor is
configured to communicate a valid start bit followed by subsequent
data bits of a signal to be transmitted via the power lines.
Referring to Table 3 below, the serial data signal includes one or
more data bits, the first data bit of which includes a destination
node or address that the serial data signal is intended to be
received at. The serial data signal further includes a subsequent
data bit that includes the sender's node or address, and may
further include a subnet node or address. The data signal may
further include a node type data bit and device request data bit,
which permits a controller (such as a thermostat) to take control
of the communication transmissions being sent over the two-wire
"bus" network lines.
TABLE-US-00003 TABLE 3 Message Configuration Addressing Messages
Byte 0 3.sup.rd Party Special Function Bytes 8- Destination Byte 1
Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 (N - 2) CRC Node Sender Byte 2
Node Device Payload Message Packet Payload Data Bytes N Address
Address Subnet Type Request Config Type Number Length Payload
Checksum 8 Bits 8 Bits 8 Bits 8 Bits 4 Bits 4 Bits 8 Bits 1 Byte 1
Byte 1 to 245 2 Bytes bytes (0-255) (1-255) (0-255) (0-255) (0-15)
(0-15) (0-255) (0-255) (0-245) (1-N) (0-65535)
[0064] The serial data signal transmitted by the controllers
includes a node type data bit, which permits controllers that are
capable of a listen mode to monitor signals transmitted by other
controllers, such that one or more listening controllers may modify
the operation of their respective HVAC components in response to
operating information signals transmitted by other controllers. For
example, if an outdoor compressor unit controller communicates a
signal indicating that the compressor has been restricted to low
capacity operation, the indoor air handler unit controller
listening to the signal could respond to the operating information
by modifying operating of the circulator blower to a reduced speed
that corresponds with the low capacity compressor operation. Node
types could include controllers for any of the following number of
HVAC components or subsystems listed in Table 4 below.
TABLE-US-00004 TABLE 4 Node Types Node Type Node ID Thermostat 0
Gas Furnace 1 Air Handler 2 Unitary Air Conditioner 3 Unitary Heat
Pump 4 Electric Furnace 5 Package System (Gas) 6 Packager System
(Electric) 7 Ceiling fan 8 Whole house fan 9 Air Exchanger 10
Dehumidifier 11 Electronic Air Cleaner 12 ERV 13 Humidifier (Evap)
14 Humidifier (Steam) 15 HRV 16 IAQ Analyzer 17 Media Air Cleaner
18 Zone control 19 Zone master 20 UV Light 21 Boiler 22 Gas Water
Heater 23 Electric Water Heater 24 Commercial Water Heater 25 Pool
Heater 26 Bus Interface Module 27 Gateway 28 Diagnostic Device 29
Lighting Control 30 Security System 31 Fuel cell 32 Spare
33-255
[0065] In the various embodiments, the controllers monitor the 24
volt waveform conducted via the two-wire "bus" network lines for
transmission signals, and are capable of listening to data signals
from various transmission sources that are intended for a different
destination address (or controller). While a signal may be intended
for a given destination address, other controllers may still
"listen" to or receive these signals and analyze them depending on
the node type of the sender of the signal. The listening mode of
the controllers provides for sharing information that reduces the
number of signal transmissions by eliminating request signals for
information, and also provides for improved diagnostic capability,
component safety, fault protection, and occupant safety.
[0066] For example, a transmitted signal may includes a source
address and node type of a controller for an outdoor air
conditioner compressor unit (eg-unitary air conditioner node ID 3)
and a destination address of the thermostat, and may communicate
diagnostic information of a high Discharge Line Temperature (DLT)
upon start up of the compressor, indicating a possible low
refrigerant charge that may require servicing. A controller for the
indoor air handler may listen to the message from the compressor
unit node type, and responsively compare the sensed temperature
difference across the indoor A-coil to a predetermined delta to
evaluate whether the difference is out of range, which would
confirm that the refrigerant charge is low. The indoor air handler
controller could then communicate a confirmation of a low
refrigerant charge to the thermostat controller, to prompt the
thermostat to alert the occupant of the need for servicing of the
low charge condition.
[0067] In another example, a thermostat controller could transmit a
signal to a controller 408 for a compressor of an air conditioning
or heat pump system to request operation of the compressor. The
controller 408 of the air handler's circulating air blower could
"listen" to or receive the signal and responsively check its line
voltage level sensing circuitry associated with a variable speed
inverter driver for a blower motor, to verify that the line voltage
level is not below a threshold value indicative of a brown out
condition. If the circulating air blower controller 452 determines
that a low line voltage condition exists, the circulating air
blower controller 452 could transmit a signal including the low
line voltage information to the compressor controller 408, which
could responsively discontinue operation to protect the compressor
from being damaged by the low voltage condition. This type of
interactive communication can accordingly provide component
protection against damage for one of more components in the climate
control system.
[0068] In another example, occupant safety is provided in a
situation of a presence of an unsafe level of carbon monoxide. In a
climate control system that at least includes a fuel-fired heating
system and a thermostat controller in connection with a common and
two-wire "bus" network lines, the system may further include a
fuel-fired water heater in connection with the two-wire "bus"
network lines. A controller for the fuel fired water heater is
connected to the two-wire "bus" network lines and is capable of
receiving and transmitting signals superimposed onto the low
frequency low-voltage waveform. The fuel-fired heating system
controller 442 is capable of modifying the operating of the heating
system by shutting down, in response to "listening" to a signal
transmitted by the water heater controller that is intended for the
thermostat controller 420, which includes information about the
presence of a harmful level of carbon gas or a presence of
flammable vapors. In either case, the furnace or heating system
would discontinue operation to help improve the safety of the
occupants. Likewise, a carbon monoxide detector could also be
configured to provide an indication of a harmful carbon monoxide
level which may be communicated through a high frequency signal
superimposed onto the low frequency low-voltage waveform to alert
the thermostat controller. The heating system controller would be
capable of "listening" to or receiving the signal intended for the
thermostat which includes information about a harmful carbon
monoxide level, and responsively discontinues operation of the
heating system.
[0069] The usage of node types is one way of receiving data from
other devices on the network without having to initiate a request
signal for information. The various controllers or subsystem
devices can operate in a listen mode to monitor signals transmitted
by certain node types to get information from certain subsystem
devices or controllers. Alternatively, the controllers can also
request transmission of information from other controllers. In
order to determine what can be requested from other controllers
that are in communication via the two-wire "bus" network, a
controller device may transmit a device request to query what types
of devices are present.
[0070] The serial data signal transmitted by the controllers
includes a device request bit, which enables a controller to
request another controller that is currently communicating to allow
access, such that the requesting controller may be allowed to
communicate a request for specific information from another
controller in a peer-to-peer manner. For example, if an outdoor
compressor unit controller detects a possible low refrigerant
charge condition, the outdoor compressor unit controller could
request the indoor air handler controller to communicate specific
information relating to whether the sensed temperature difference
across the A-coil is out of range, which would confirm that the air
conditioner refrigerant charge is low. This information may also be
communicated to the thermostat to alert an occupant of the low
refrigerant charge condition.
[0071] In some embodiments, a communication coordinator may be
employed in connection with the two-wire "bus" network lines. Where
a communication coordinator is used, a controller device may
transmit via the two-wire "bus" network lines a request of the
coordinator to provide a network configuration request. The request
is made after the coordinator makes a periodic request of
subordinate device status. This would allow an individual
controller to include itself in the network of other controllers
identified by the coordinator. Each controller device (or node) may
further communicate a request to the communication coordinator
(after the coordinator makes a periodic request of subordinate
device status) to take control of the communication being sent
across the power lines, for enabling the requesting controller to
transmit a signal intended for another controller. The coordinator
would respond by sending signals to controllers other than the
requesting controller to suspend transmission until the next
periodic request for status by the coordinator. The requesting
controller could then transmit a signal intended for another
controller that contains a request for operation, or relevant
operating information, for example. In this manner, each controller
may communicate to other controllers via the power lines without a
likelihood of signal interference, since the transmitting control
would have dominant control over the lines.
[0072] The serial data signal transmitted by the controllers
includes a payload data configuration byte. The payload
configuration bits are used in determining what type of data packet
is being received. These bits are located in byte 3 of every data
packet sent in bits 0-3. The message type is contained in Byte 5 of
the packet, and may provide information as to whether the signal is
interrogating or requesting information from another controller or
a component, whether the signal is of a sensor data type, whether
the signal is a unique command signal intended for a specific
controller or component in the system, or whether the signal is an
operating informational message intended for a specific controller
in the system, such as a thermostat. The message may be a code
which other controllers may recognize. The message may also be a
text message, as opposed to a fixed-digit code that the thermostat
must look up to display a corresponding message to an occupant. In
this manner, a controller may provide more specific repair or
maintenance information than just a code. Table 5 below outlines
some of the message types that may be employed in the various
embodiments. It should be noted that any one of a number of
controllers communicating via the network may prompt the thermostat
to display a variable length text message, as indicated in message
type 20. This feature allows for thermostat compatibility with
newer version controllers that may be installed or upgraded at a
future point in time. Such new controllers could simply send a
lengthy asci-text message including detailed diagnostic information
to the thermostat, rather than send a diagnostic code number that
the thermostat may not have within its memory and would not
recognize.
TABLE-US-00005 TABLE 5 Message Type. Message Type Message Name
Description 0 Ready Used to make normally subordinates a
coordinator 1 Status Request Used to request operating status of a
controller 2 Status Reply or its respective components 3 Control
Command Commands a specific controller/component to operate in a
desired mode 4 Configuration Request Installation Parameter Info
used to configure 5 Configuration Data controllers and components 6
Sensor Read Request Serial communication by any external/internal 7
Sensor Data sensors in a subsystem that can be shared with the
system 8 Spare 9 Set Address 10 Event Request Request Data defined
as historical operating 11 Event Reply information of a specific
controller or component in the system. 12 ID Request Identification
Data of individual controllers 13 ID Set and components in the
system 14 ID Reply 15 Node Type Request 16 Node Type Reply 17
Message Config Request Used to determine which messages are
applicable 18 Message Config Reply per specific component or
controller in the system. 19 Display Control Used to take control
of the thermostat display Request to provide
installation/diagnostic/System Checks 20 Display Control Reply or
any other subsystems needs. (text message may vary in length) 21
Shared Device Data Installation Specific Configuration Data used
Request for transmitting data to shared networks or external
network
[0073] The one or more controllers may transmit text messages to a
thermostat controller to alert an occupant of specific maintenance
requirements, such as a dirty air cleaner in need of filter
replacement, or an outdoor compressor with a low refrigerant
charge, as shown in FIGS. 5 and 6. The thermostat may be prompted
by a transmitting controller to display both a text message and
also a "cancel" or "clear" icon. The occupant may accordingly view
the message, replace the filter for example, and clear the signal
communicating a maintenance requirement. The thermostat may also be
prompted by a transmitting controller to display both a text
message and a "service" icon. Where a service icon is displayed,
the occupant may select the service icon by touching a button, upon
which the thermostat may display a text message of a service
contractor's name and phone number, which could be customized by a
service contractor installing the thermostat controller.
[0074] In the various embodiments of an interactive system
comprising two or more controllers for controlling a plurality of
HVAC components, the controllers may be incrementally installed and
connected to the network without requiring the installation of a
master thermostat for controlling communication between the
controllers. In yet another exemplary embodiment, a home-owner may
decide to install a second air conditioning system for a second
floor of a home that has an existing air conditioning system
including interactive controllers and a thermostat controller in
connection with a network. The existing controllers communicate to
an existing interactive thermostat controller, which may further be
used to control the new second floor air conditioning system
controllers. The new controllers for the new air conditioning
components and a new temperature sensor associated with the new
controllers (for the second floor) may be connected to the network.
The new temperature sensor subsequently sends signals including
temperature information, and the new controllers also send status
signals, via the network. Such signals may be addressed to a
default thermostat type. The existing thermostat controller would
be capable of listening to the signals transmitted by the
temperature sensor and the new controllers, regardless of whether
the signal is addressed to or intended for the existing thermostat.
Upon monitoring a signal from the new controllers and the new
temperature sensor, the existing thermostat controller could
responsively communicate a signal to the new controllers to modify
the operation of the second system, e.g., to activate the system.
The existing thermostat controller can then monitor the signals
transmitted by the new temperature sensor to determine whether the
temperature is decreasing in response to its request of the new
controllers to establish operation of the second cooling system.
Thus, the existing thermostat controller is interactively capable
of associating the new controllers and the new temperature sensor,
and subsequently controlling the new second air conditioning system
via the network.
[0075] In the above exemplary embodiment, the existing thermostat
controller may alert the user of the detection of a second air
conditioning system, by displaying this on the thermostat's
display. Accordingly, the existing thermostat controller can allow
the user of the thermostat to then enter a set-point temperature
for each air conditioning system, each of which will control
operation of their respective air conditioning system. Thus, the
user may control the operation of the new controllers in the second
system without knowing their specific node types or addresses.
[0076] In the above exemplary embodiment, the existing thermostat
controller may optionally, but not necessarily, identify each of
the new controllers associated with the second air conditioning
system as a sub-node type (see Table 5). The existing thermostat
controller may simply assign a node type for each of the new
controllers within an internal memory of the thermostat. The
thermostat optionally may communicate a signal including a sub-node
identification to each of the new controllers that the existing
thermostat controller has associated with the new temperature
sensor (which new controllers would store the sub-node type). By
identifying the new controllers as a particular sub-node type, the
existing thermostat controller can then display to the user the
sub-node type associated with the new second system controllers. A
user or a service repairman would then be able to distinguish
controllers of the second system by the displayed sub-node type,
such that the user or repairman can select a particular controller
within the second air conditioning system to request operational or
diagnostic information pertaining to the second air conditioning
system (as opposed to information pertaining to the existing air
conditioning system). The existing thermostat, by at least
internally assigning a sub-node type to the second system
controllers (but not necessarily assigning a sub-node address to
the individual controllers), would allow the thermostat to function
as a user-interface that would allow the user to gain access to the
new controllers of the second air conditioning system without
having to know their respective addresses or node types. This
exemplary system is notably different from "master-slave"
thermostat situations, which would not permit the new controllers
to communicate via the network to other controllers until each new
controller is manually set-up or configured through the master
thermostat.
[0077] In the above exemplary embodiment, the existing thermostat
controller can automatically identify and associate the new
controllers of the second air conditioning system as described
above, and can further allow a user to utilize the thermostat
controller as an interface to gain access to the new controllers of
the second air conditioning system for modifying their default
settings without having to know their respective addresses or node
types. While each of the new controllers of the second air
conditioning system may each be modified from their default
operating configuration by manually accessing each control at its
respective location, the new controllers may also be communicated
to via the network through a thermostat controller in connection
with the network. For example, a controller for an indoor air
handler associated with the second air conditioning system may have
a default time delay period in which the circulator blower remains
on after discontinuation of compressor operation, which time period
may be altered by a user. Rather than the user having to go to the
location of the specific controller and manually entering a
setting, by pressing a button a certain number of times for
example, the user may prompt the thermostat to display the settings
of a selected controller. The user may then modify or select a
different setting, which the thermostat controller would then
communicate via the network to the selected controller such that
the controller may change its default setting.
[0078] In the above exemplary embodiment, the homeowner may
optionally choose to install a second thermostat controller on the
second floor of the home, which second thermostat could be
connected to the network. The existing thermostat controller can
automatically identify the second thermostat controller, for
communicating the node types of either the existing air
conditioning controllers, the node types of the second air
conditioning controllers, or both. Likewise, the existing
thermostat controller can further allow a user to utilize the
existing thermostat controller as an interface to gain access to
the second thermostat controller of the second air conditioning
system for remotely configuring or modifying the second
thermostat's settings. For example, the thermostat controller may
display a screen (when prompted) that includes a "PROGRAM" or other
suitable icon selection as shown in FIG. 7. The user may press a
button to program the present thermostat controller that the user
is viewing, or the user may continue to press the button to select
other controllers that the user may want to communicate setting
information to. For example, the user may press a button to select
programming of a second thermostat controller as shown in FIG. 8.
The thermostat controller viewed by the user would then communicate
a request to the second thermostat controller to provide setting
information (such as programmed temperature settings as shown in
FIG. 8). The first thermostat controller that the user is viewing
would then display the settings communicated from the second
thermostat controller (such as programmed temperature settings as
shown in FIG. 8). Rather than the user having to go to the location
of both the first and second thermostat controllers and enter
settings at each location, the user may simply enter selections for
the second thermostat controller from the first thermostat
controller. The user accordingly may remotely modify the settings,
which the first thermostat controller would then communicate via
the network to the selected controller such that the second
thermostat controller may change its settings.
[0079] The various embodiments provide for one or more controllers
in connection with a communication network for enabling
transmission of signals addressed to or intended for a specific
controller. While each signal may be intended for a specific
controller, at least one controller may listen to signals intended
for other controllers and may modify the operation of at least one
component that the at least one controller has control over in
response to receiving a signal that is intended for another
controller which includes information about the operation of a
component within the system. The controllers in the various
embodiments are capable of providing cooling or heating operation
in a "limp along" mode, while alerting the occupant of service or
repair needs via a text message before the system becomes
inoperable. The description of the disclosure is merely exemplary
in nature and, thus, variations that do not depart from the gist of
the disclosure are intended to be within the scope of the
disclosure. Such variations are not to be regarded as a departure
from the spirit and scope of the disclosure.
* * * * *