Thermostat circuitry for connection to HVAC systems
09605858 ยท 2017-03-28
Assignee
Inventors
- Daniel Adam Warren (San Francisco, CA, US)
- Hugo Fiennes (Palo Alto, CA, US)
- Jonathan Alan Dutra (Saratoga, CA, US)
- David Bell (Los Altos Hills, CA, US)
- Anthony Michael Fadell (Portola Valley, CA, US)
- Matthew Lee Rogers (Los Gatos, CA, US)
Cpc classification
Y02B10/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24F2130/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/56
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02D30/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24F11/63
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F2140/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H04W4/70
ELECTRICITY
F24F2110/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/52
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F2140/60
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/89
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F2110/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/62
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/47
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y10T29/49826
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02B10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24F11/39
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01R9/2416
ELECTRICITY
F24F2120/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/64
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F2120/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/46
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
H04W4/00
ELECTRICITY
F24D19/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D46/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A thermostat and related methods is provided for controlling an HVAC system having one or two separate transformers for supplying power to the HVAC system. The thermostat includes isolation circuitry housed within the thermostat to safely connect to the HVAC control wires and power wire(s) whether the HVAC system has one or two separate transformers without the use of removable jumpers or manual rewiring. The thermostat can include a processor that sends DC signals for turning on and turning off each of the HVAC functions, and an isolator adapted to electrically isolate the processor from the control wires and power wire(s). The isolator can include a transformer, such as a low cost Ethernet transformer. The circuitry can include one or more field effect transistors adapted and arranged so as to open or close an electrical connections between the control and power wires, thereby turning on or off the associated HVAC function. According to some embodiments, the Rc and Rh terminals are permanently connected using a fuse.
Claims
1. A thermostat for controlling a heating, ventilation, and air conditioning (HVAC) system, the HVAC system having one or two HVAC transformers, one or more control wires for controlling one or more HVAC functions, and one or two power return wires, each of which is electrically connected to one of the one or two HVAC transformers, the thermostat comprising: two power return wiring terminals for making electrical connections to the one or two power return wires; a switching circuit for: maintaining an electrical connection between the two power return wiring terminals in cases without an external jumper between the two power return wiring terminals and where the HVAC system has only one HVAC transformer; and maintaining an electrical isolation between the two power return wiring terminals in cases where the HVAC system has two HVAC transformers; one or more solid state switching components adapted and arranged to turn on and off the one or more HVAC functions; a processor adapted and configured to send DC signals for turning on and off the one or more HVAC functions using the one or more solid state switching components; and one or more isolators positioned and adapted to electrically isolate the processor from the one or more solid state switching components, wherein: said one or more solid state switching components comprises, for each said one or more HVAC functions, a FET switch; said one or more isolators comprise, for each said one or more HVAC functions, a thermostat transformer; and for each said one or more HVAC function, said thermostat comprises: driver circuitry coupled between said processor and said thermostat transformer, said driver circuitry being configured to receive at least one of said DC signals from said processor and to provide an AC version thereof to a primary winding of said thermostat transformer; and rectifier circuitry coupled between a secondary winding of said thermostat transformer and said FET switch.
2. The thermostat according to claim 1 wherein the one or more solid state switching components do not reference an electrical ground.
3. The thermostat according to claim 1 wherein each said FET switch includes a first field effect transistor and a second field effect transistor, said thermostat further comprising a varistor clamp coupled between a drain of said first field effect transistor and a drain of said second field effect transistor.
4. The thermostat according to claim 1 wherein the one or more HVAC functions include heating and cooling.
5. The thermostat according to claim 1 wherein the HVAC system is a residential HVAC system.
6. The thermostat according to claim 1 wherein the HVAC system is a light commercial HVAC system.
7. The thermostat according to claim 1 wherein one of the one or more HVAC functions is cooling, and the HVAC system has a cooling capacity of less than about 5 tons.
8. The thermostat according to claim 1 further comprising circuitry connected to the one or more solid state switching components, the circuitry and the solid state switching components adapted and arranged such that the switching is left in an open state in the event of a failure condition within the thermostat.
9. The thermostat according to claim 1 further comprising current sensing circuitry adapted and arranged to sense current passing through the one or more solid state switching components.
10. The thermostat according to claim 9 wherein the current sensing circuitry includes circuitry to measure a voltage differential across at least one of the one or more solid state switching components.
11. The thermostat according to claim 9 wherein the current sensing circuitry includes measuring a voltage differential across a thermistor in series with at least one of the one or more solid state switching components.
12. The thermostat according to claim 1 wherein said driver circuitry includes an AC coupling capacitor coupled to said primary winding of said thermostat transformer for preventing DC current from flowing into said thermostat transformer.
13. The thermostat according to claim 1 wherein the switching circuit includes one or more switches adapted to automatically electrically disconnect the two power return wiring terminals in cases where two power return wires are connected to the two power return wiring terminals.
14. The thermostat according to claim 13 wherein at least one of the one or more switches is mechanically actuated when a connection of a wire is made to one of the two power return wiring terminals.
15. The thermostat according to claim 1 further comprising one or more detection circuits adapted and arranged to detect whether the HVAC system has one or two HVAC transformers.
16. The thermostat according to claim 1 wherein the switching circuit electrically connects or disconnects the two power return wiring terminals based at least in part on input from a user interface.
17. The thermostat according to claim 1 wherein the switching circuit includes a relay.
18. The thermostat according to claim 1 wherein the switching circuit includes second one or more solid state switching components.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The inventive body of work will be readily understood by referring to the following detailed description in conjunction with the accompanying drawings, in which:
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DETAILED DESCRIPTION
(10) A detailed description of the inventive body of work is provided below. While several embodiments are described, it should be understood that the inventive body of work is not limited to any one embodiment, but instead encompasses numerous alternatives, modifications, and equivalents. In addition, while numerous specific details are set forth in the following description in order to provide a thorough understanding of the inventive body of work, some embodiments can be practiced without some or all of these details. Moreover, for the purpose of clarity, certain technical material that is known in the related art has not been described in detail in order to avoid unnecessarily obscuring the inventive body of work.
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(13) Thermostat 110 controls the HVAC system 120 through a number of control circuits. In particular, there is often separate control systems for heating and cooling. The heating system can include a low voltage, for example 24 VAC, operated gas valve which controls the flow of gas to the furnace, the cooling system includes a contactor having a low-voltage coil and high-voltage contacts which control energizing of the compressor; and the circulation system includes a fan relay having a low-voltage coil and high-voltage contacts which control energizing of the fan which circulates the conditioned air. The electrical power for energizing such low-voltage operated devices is provided either by a single transformer 260 for both heating and cooling, or by two separate transformers 260 for heating and 262 for cooling. Often, a single transformer is provided when the heating and cooling system is installed as a complete unit. If the cooling system is added to an existing heating system, sometimes an additional transformer is used.
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(15) The HVAC functions are controlled by the HVAC control general purpose input/outputs (GPIOs) 322 within MCU 320. MCU 320 is a general purpose microcontroller such as the MSP430 16-bit ultra-low power MCU available from Texas Instruments. MCU 320 communicates with the head unit via Head Unit Interface 340. The head unit together with the backplate make up the thermostat. The head unit has user interface capability such that it can display information to a user via an LCD display and receive input from a user via buttons and/or touch screen input devices. According to some embodiments, the head unit has network capabilities for communication to other devices either locally or over the internet. Through such network capability, for example, the thermostat can send information and receive commands and setting from a computer located elsewhere inside or outside of the enclosure. The MCU detects whether the head unit is attached to the backplate via head unit detect 338.
(16) Clock 342 provides a low frequency clock signal to MCU 320, for example 32.768 kHz. According to some embodiments there are two crystal oscillators, one for high frequency such as 16 MHz and one for the lower frequency. Power for MCU 320 is supplied at power input 344 at 3.0 V. Circuitry 336 provides wiring detection, battery measurement, and buck input measurement. A temperature sensor 330 is provided, and according to some embodiments and a humidity sensor 332 are provided. According to some embodiments, one or more other sensors 334 are provided such as: pressure, proximity (e.g. using infrared), ambient light, and pyroelectric infrared (PIR). Power circuitry 350 is provided to supply power.
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(18) Inputs 401a and 401b are a logic level clock signal from the MCU, and are preferably differential signals. Inputs 401a and 401b generate the frequency that is coupled across the isolation component. According to some embodiments, inputs 401a and 401b are not a fixed frequency, but rather a spread spectrum. Input 402 enables the AND gates 403. AND gates 403 are AND logic gates that generate a buffered AC signal for driving the transformer 432. An example of a suitable logic component for AND gates 403 is a dual buffer/driver such as the SN74LVC2G08 from Texas Instruments.
(19) AC coupling capacitor 404, this component prevents DC current from flowing in the transformer, which would reduce efficiency and could hurt operation due to transformer saturation. Resistors 405a and 405b work in conjunction with stray capacitances to round the sharp edges of the clock signals, limit instantaneous currents, and damp resonant circuits. This reduces EMI.
(20) It should be noted that other topologies of driver circuits could be used for 401-405 above, according to other embodiments. The embodiment shown in
(21) Transformer 432 includes primary winding 406 and secondary winding 407. The transformer 432 provides isolation, such that the switch could be many volts different potential from the control circuitry. According to some embodiments, transformer 432 is an Ethernet transformer. Ethernet transformers have been found to work well with a very low cost. According to the other embodiments, other styles of transformers could be used. According to some embodiments, coupled inductors such as LPD3015 series from Coilcraft are used. According to some embodiments, the transformer 432 is replaced with capacitors, as this is an alternative way to get AC energy across a boundary 430.
(22) The transformer 432 has a turns ratio of 1:1 primary winding 406 to secondary winding 407, although other windings ratios can be used according to other embodiments. With 3 volts across the primary of the transformer, a 1:1 ratio transformer generates about +6 volts of gate to source voltage on the FETs 424 and 425. The topology shown is a modified push pull. According to other embodiments, other topologies including forward, flyback, and push pull could be used. Resistors 409a and 409b work in conjunction with stray capacitances to round the sharp edges of the clock signals, limit instantaneous currents, and damp resonant circuits. This reduces EMI.
(23) AC coupling capacitor 410 accumulates a DC voltage across it in normal operation which is approximately the output gate to source voltage divided by 2. This capacitor 410 allows the transformer 432 to be used more effectively than if it was not there. If the output voltage is half what it should be, this capacitor 410 is likely shorted.
(24) Bottom diode 411 is on for half the cycle, and enables the capacitor 410 to charge to half the output voltage. Top diode 412 is on for the other half of the cycle, and basically peak detects the voltage on the capacitor 410 with the voltage across the transformer, resulting in a rectified output voltage across capacitor 419.
(25) Circuit 450 is used to enable a fast turn off characteristic. When the voltage on the Switch Gate is rising with respect to the Switch Source, capacitor 413 charges up through diode 414. When the voltage on the Switch Gate drops with respect to the Switch Source, this capacitor 413 pulls down on the emitter of NPN 416 which turns on 416, which turns on 417, which discharges 419 (as well as the capacitances of the MOSFETs 424 and 425) and quickly turns off the switch. This fast turn off characteristic may be useful in an energy harvesting application such as described in greater detail in co-pending U.S. patent application Ser. No. 13/034,678 entitled Thermostat Battery Recharging filed on even date herewith, and which is incorporated herein by reference. Capacitor 415 may be helpful in EMI immunity tests. Resistor 418 prevents PNP 417 from turning on due to leakage currents.
(26) Resistor 420 discharges the gate source capacitance voltage and tends to turn off the switch, and to hold it off when no control signal is present. Gate resistor 422 prevents the FETs 424 and 425 from oscillating due to their follower topology. Zener diode 423 prevents the gate to source voltage from going too high, which could damage the FETs 424 and 425.
(27) FETs 424 and 425 are the main switching elements in the circuit 400. FETs 424 and 425 tend to be on when the gate to source voltage is above the threshold voltage of the FETs, and tend to be off when the gate to source voltage is less than the threshold voltage. As this is a bidirectional AC Switch, two FETs are used because available FETs have a drain to source body diode, and if only one FET were used the switch would be On due to the body diode for half of the AC cycle.
(28) Note that the with the circuit of
(29) According to some embodiments, the circuitry 450 provides for the connection between terminals 442 and 444 to be open very quickly when the control signal is received from the driver circuit. According to some embodiments the fast turn-off circuitry 450 is used for isolated FET drives for HVAC wires used for power harvesting, such as W (heating) and Y (cooling), but is omitted from other isolated FET drives that are not used for power harvesting, such as for Aux, G (fan), and O/B (compressor direction).
(30) Additionally, the circuitry shown in
(31) According to some embodiments, the thermostat carries out current sensing through the HVAC control circuit by detecting the voltage across the FETs 424 and 425. Unlike most thermostats, that use mechanical relays having virtually no measurable voltage drop to open and close the HVAC control circuit for the HVAC function, the thermostat as described herein uses solid state switching which has enough voltage drop so as to allow for current measurements. In the case of
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(34) Relay 670 controls the gas valve for the HVAC heating system. When sufficient AC current flows through the gas valve relay 670, gas in the heating system is activated. The gas valve relay 670 connected via a wire to terminal 684, which is labeled the W terminal, on thermostat 610. Relay 672 controls the fan for the HVAC heating and cooling systems. When sufficient AC current flows through the fan relay 672, the fan is activated. The fan relay 672 connected via a wire to terminal 682, which is labeled the G terminal on thermostat 610. Contactor (or relay) 674 controls the compressor for the HVAC cooling system. When sufficient AC current flows through the compressor contactor 674, the fan is activated. The contactor 674 connected via a wire to terminal 680, which is labeled the Y terminal, on thermostat 610. The heat power transformer 660 is connected to thermostat 610 via a wire to terminal 692, which is labeled the Rh terminal. The cooling power transformer 662 is connected to thermostat 610 via a wire to terminal 690, which is labeled the Rc terminal.
(35) Thermostat 610 includes three isolated FET drives 630, 632 and 634 for switching open and close the AC current to each of the relays 670, 672 and 674. Note that according to some embodiments, each of the FET drives 630, 632 and 634 are of the design of sub-circuit 400 as shown and described with respect to
(36) Drive 630 includes a switching portion 640 for opening and closing the AC current between terminal 680 and terminal 690, thereby controlling the compressor contactor 674 of the HVAC cooling system. The drive portion 640 is controlled by and isolated from, via a transformer, driver circuit 650. The MCU 620 controls driver circuit 650. Drive 632 includes a switching portion 642 for opening and closing the AC current between terminal 682 and terminal 690, thereby controlling the fan relay 672 of the HVAC heating and cooling systems. The drive portion 642 is controlled and isolated from, via a transformer, driver circuit 652. The MCU 620 controls driver circuit 652. Drive 634 includes a switching portion 644 for opening and closing the AC current between terminal 684 and terminal 692, thereby controlling the gas valve relay 670 of the HVAC system. The drive portion 644 is controlled by and isolated from, via a transformer, driver circuit 654. The MCU 620 controls driver circuit 654. Note that although the drive portions 640, 642 and 644 are isolated from the driver circuits 650, 652 and 654 respectively by a transformer, other isolation means could be provided as described with respect to
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(39) Relay 770 controls the gas valve for the HVAC heating system. When sufficient AC current flows through the gas valve relay 770, gas in the heating system is activated. The gas valve relay 770 connected via a wire to terminal 784, which is labeled the W terminal, on thermostat 710. Relay 772 controls the fan for the HVAC heating and cooling systems. When sufficient AC current flows through the fan relay 772, the fan is activated. The fan relay 772 connected via a wire to terminal 782, which is labeled the G terminal on thermostat 710. Contactor (or relay) 774 controls the compressor for the HVAC cooling system. When sufficient AC current flows through the compressor contactor 774, the fan is activated. The contactor 774 connected via a wire to terminal 780, which is labeled the Y terminal, on thermostat 710. The heat power transformer 760 is connected to thermostat 710 via a wire to terminal 792, which is labeled the Rh terminal. The cooling power transformer 762 is connected to thermostat 710 via a wire to terminal 790, which is labeled the Rc terminal.
(40) Thermostat 710 includes three isolated FET drives 730, 732 and 734 for switching open and close the AC current to each of the relays 770, 772 and 774. Note that according to some embodiments, each of the FET drives 730, 732 and 734 are of the design of sub-circuit 400 as shown and described with respect to
(41) Drive 730 includes a switching portion 740 for opening and closing the AC current between terminal 780 and terminal 790, thereby controlling the compressor contactor 774 of the HVAC cooling system. The switching portion 740 is controlled by and isolated from, via a transformer, driver circuit 750. The MCU 720 controls driver circuit 750. Drive 732 includes a switching portion 742 for opening and closing the AC current between terminal 782 and terminal 790, thereby controlling the fan relay 772 of the HVAC heating and cooling systems. The drive portion 742 is controlled and isolated from, via a transformer, driver circuit 752. The MCU 720 controls driver circuit 752. Drive 734 includes a switching portion 744 for opening and closing the AC current between terminal 784 and terminal 792, thereby controlling the gas valve relay 770 of the HVAC system. The drive portion 744 is controlled by and isolated from, via a transformer, driver circuit 754. The MCU 720 controls driver circuit 754. Note that although the drive portions 740, 742 and 744 are isolated from the driver circuits 750, 752 and 750 respectively by a transformer, other isolation means could be provided as described with respect to
(42) Two normally-closed switches 716 and 726 are provided between the Rc terminal 790 and the Rh terminal 792. Switch 716 is automatically opened when the presence of a wire connected to the Rc terminal 790 is detected, and switch 726 is opened automatically when the presence of a wire connected to Rh terminal 792 is detected. According to some embodiments, the switches 716 and 726 are provided using a connector as described in co-pending U.S. patent application Ser. No. 13/034,666 entitled Thermostat Wiring Connector, filed on even date herewith and incorporated herein by reference. In particular, the switches 726 and 716 can correspond to the switched pairs of secondary conductors 750 in
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(45) Relay 870 controls the gas valve for the HVAC heating system. When sufficient AC current flows through the gas valve relay 870, gas in the heating system is activated. The gas valve relay 870 connected via a wire to terminal 884, which is labeled the W terminal, on thermostat 810. Relay 872 controls the fan for the HVAC heating and cooling systems. When sufficient AC current flows through the fan relay 872, the fan is activated. The fan relay 872 connected via a wire to terminal 882, which is labeled the G terminal on thermostat 610. Contactor (or relay) 874 controls the compressor for the HVAC cooling system. When sufficient AC current flows through the compressor contactor 874, the fan is activated. The contactor 874 connected via a wire to terminal 880, which is labeled the Y terminal, on thermostat 810. The heat power transformer 860 is connected to thermostat 810 via a wire to terminal 892, which is labeled the Rh terminal. The cooling power transformer 862 is connected to thermostat 810 via a wire to terminal 890, which is labeled the Rc terminal.
(46) Thermostat 810 includes switching circuits 830, 832 and 834 for switching open and close the AC current to each of the relays 870, 872 and 874 under the control o MCU 820. According to some embodiments, the circuits 830, 832 and 834 could be relays. According to other embodiments, switching circuits 830, 832 and 834 could be implemented using isolated FET drives such as shown in
(47) According to some embodiments, thermostat 810 includes two auto detection circuits 840 and 842 to detect whether an AC signal is being applied to terminals 890 and 892 respectively. According some embodiments, a half-bridge sense circuit such as shown and described with respect to
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(49) According to some embodiments, user input is used to control switching circuit 836 instead of, or in addition to using auto detection circuits 840 and 842. According to such embodiments, user input is provided via a user interface such as button on the head unit of thermostat 810 (not shown), and in response, the MCU 820 opens or closes the switching circuit 836. For example, during installation, a user or installer may be queried whether the HVAC system has one or two power transformers. If the user indicates there are two HVAC power transformers than the switching circuit 836 is opened and if the user indicates there is only one HVAC power transformer then switching circuit 836 is closed.
(50) Although the foregoing has been described in some detail for purposes of clarity, it will be apparent that certain changes and modifications may be made without departing from the principles thereof. It should be noted that there are many alternative ways of implementing both the processes and apparatuses described herein. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the inventive body of work is not to be limited to the details given herein, which may be modified within the scope and equivalents of the appended claims.