Controller for a climate control system

A system is provided for controlling at least one climate control apparatus for conditioning a space. The system includes a controller mountable to a climate control apparatus that is segregated from the space to be conditioned. The controller has a plurality of selectable setting parameters for configuring the controller to operate at least one of a plurality of climate control apparatus, and a plurality of visual indicators for visually indicating the selection of at least one selectable setting parameter. A user interface is adapted for installation in the space, and has a display for displaying selectable setting parameters for configuring the controller. The user interface includes user input controls for enabling selection of at least one displayed selectable setting parameter, where the controller responsively activates at least one visual indicator for indicating the selection of at least one selectable setting parameter by the user-interface.

FIELD OF THE INVENTION

The present invention relates to controls for controlling residential heating, ventilation and air conditioning systems.

BACKGROUND OF THE INVENTION

Thermostats are typically used to control residential climate control systems, to maintain the temperature of a space relative to a set point by activating a heating or air conditioning unit to heat or cool the space. Some heating systems may include a fuel-fired heating apparatus, while others include a heat pump or an electric heat system. Air conditioning units provide conditioned air for cooling the space, while humidity controls provide for humidification or dehumidification. Depending on which systems are installed, different controllers are required for controlling activation of various components of a gas-fired heating unit, for example, or alternatively components of a heat pump. In the case of a heat pump with a back-up electric heat unit, the electric heat may also be turned on when the heat pump is not providing adequate heat. However, installation of such controllers requires identification of the specific types of air conditioning, heat pump and electric/gas heating systems used and the connections required for such systems. The complexities involved with the above can result in problems with incorrect configured or miss-wired systems.

SUMMARY OF THE INVENTION

Various embodiments of a controller are provided for controlling various types of climate control apparatus, such as heating, air conditioning and humidity control apparatus. In one preferred embodiment, a system is provided for controlling at least one climate control apparatus for conditioning a space. The system includes a controller mountable to a climate control apparatus that is segregated from the space to be conditioned. The controller has a plurality of selectable setting parameters for configuring the controller to operate at least one of a plurality of climate control apparatus, and a plurality of visual indicators for visually indicating the selection of at least one selectable setting parameter. A user interface is adapted for installation in the space, and has a display for displaying selectable setting parameters for configuring the controller. The user interface includes user input controls for enabling selection of at least one displayed selectable setting parameter, where the controller responsively activates at least one visual indicator for indicating the selection of at least one selectable setting parameter by the user-interface, to thereby provide confirmation of the setting selection.

In some embodiments, the system includes a controller that is mountable to a climate control apparatus segregated from the space, which includes input means for receiving communication of information indicating the selection of at least one selectable setting parameter for configuring the controller. A user interface is releasably connectable to a sub-base that is adapted for installation within the space to be conditioned. The user interface includes a display for displaying selectable setting parameters for configuring the controller, and user input controls for enabling selection of at least one of the displayed selectable setting parameters. A communication means provides for communication of information from the user interface to the input means of the controller, where the information indicates the selection of at least one selectable setting parameter. The user-interface is releasable from the sub-base and connectable to the controller, to enable selection of at least one selectable setting parameter via the user interface at the location of the controller, such that the controller can be configured to control operation of one or more climate control apparatus.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. According to one aspect of the present disclosure, embodiments of a system are provided for controlling various climate control apparatus for conditioning a space. The system includes a controller mountable to a climate control apparatus that is segregated from the space. The controller has selectable setting parameters for configuring the controller to control at least one of a plurality of climate control apparatus, and a plurality of visual indicators for indicating the selection of at least one setting parameter. A user interface is adapted for installation in the space, and has a display for displaying selectable setting parameters for configuring the controller, and user-input controls for selection of at least one displayed selectable setting parameter. The controller activates at least one visual indicator for indicating a selection of at least one selectable setting parameter by the user-interface.

In some embodiments, the system includes a controller mountable to a climate control apparatus segregated from the space, where the controller includes input means for receiving communication of information indicating a selection of at least one of a plurality of selectable setting parameters. A user interface is releasably connectable to a sub-base installed within the space. The user interface includes a display for displaying selectable setting parameters for configuring the controller, and user input controls for enabling selection of at least one of the displayed selectable setting parameters. A communication means communicates information from the user interface to the controller that indicates the selection of at least one selectable setting parameter. The user-interface is releasable from the sub-base and connectable to the controller to enable selection of at least one selectable setting parameter via the user interface at the location of the controller, such that the controller can be easily configured to control one or more climate control apparatus, as explained below.

Referring toFIG. 1, various types of climate control apparatus for conditioning a space10are shown. The various climate control systems preferably include an indoor air circulation unit12, which may include a burner associated with a gas-fired heating unit14. Alternatively, the heating unit may utilize electric heating elements16associated with indoor air circulation unit12. The climate control system may further include an air conditioner unit20having a compressor22, a condenser coil24and an A-coil18for providing cooling operation. The air conditioner compressor22may also be utilized with a reversing valve26in a heat pump mode, to provide for heating in combination with or in place of a gas or electric heating unit. The climate control system may further include a humidity control32, such as a humidifier/dehumidifier. A controller100may control a switch for applying a voltage (via controller100) for activating the humidity control at the same time as the indoor air circulation unit12. Alternatively, where the humidity control is self-powered, the controller100may close a connection for activating the self-powered humidity control device.

According to one aspect of the present disclosure, a controller100is provided that is configurable for controlling operation of a plurality of climate control apparatus, such as those described above. As shown inFIG. 1, a climate control apparatus (e.g., air circulation unit12) may be disposed in a basement or a closet. A controller100is disposed in close proximity to indoor air circulation unit12(or heating/air conditioning unit), such that the controller100is disposed outside of or segregated from the space10. The controller100is configured to receive temperature information from at least one temperature sensing device disposed within the space10. Preferably, the temperature sensing device is a user interface38that is capable of communicating temperature information to the controller100. As shown inFIG. 1, the user interface38is wired to controller100via at least two wires54,56, but may be in wireless communication with the controller100. Alternatively, a thermostat or wireless remote temperature sensor may be used. One example of a wireless remote temperature sensor is a F0148-1328 remote sensor made by White-Rodgers, a Division of Emerson Electric Co., which is disclosed in co-assigned U.S. Pat. No. 6,513,723 entitled “Method and Apparatus For Automatically Transmitting Temperature Information”, and is incorporated herein by reference.

The controller100is configured to receive the temperature information and compare it to a set-point temperature. The controller100is configured to provide commands for selectively controlling one or more switching devices for initiating activation signals to the various climate control apparatus, where the activation signals that activate each type of heating, air conditioning and/or humidity control apparatus are provided solely by the controller100(and not provided by a thermostat). Accordingly, a thermostat is not required for providing activation signals to the various climate control apparatus. The controller100may be used with or without a thermostat, and can provide all activation signals for controlling heating, air conditioning and/or humidity control operation regardless of whether input is received from a thermostat.

One example of such a controller100is disclosed in U.S. patent application Ser. No. 13/073,286 entitled “Wireless Control of a Heating or Cooling Unit,” which is incorporated herein by reference and describes a controller100segregated from the space10that can control operation of an air conditioning and/or heating unit without receiving an input from a thermostat requesting heating or cooling operation. While the above controller100is configured to control activation of apparatus independent of a thermostat, the controller100of the present disclosure may be used with a thermostat that requests activation of climate control apparatus. The controller100is configured to control a plurality of switching devices to provide activation signals to one or more climate control apparatus, based on configuration setting parameters that the controller receives from the user interface38, as explained below.

While the various embodiments of a controller100described in the present disclosure are capable of activating various heating, air conditioning and/or humidity control systems described above, each residence may have different configurations including one or more of the various described climate control apparatus. For example, some residences may have an air conditioner unit20and a gas-fired heating unit14. Some residences may only have an air conditioner unit20, or a heating system with electric heating elements16. Other residences may have a gas-fired heating unit14and a heat-pump configured air conditioner unit20with a reversing valve26. Some systems may also include back-up emergency heating via electric heating elements16. Accordingly, for each particular residence, the controller100must be configured to control the specific collection of different climate control systems within the given residence.

According to one aspect of the present disclosure, various embodiments are provided of a controller100that is disposed outside of or segregated from the space10to be conditioned, which is configurable by an associated user interface38that is adapted to be installed within the space to be conditioned. Since the controller100and the user interface38are not co-located or within visible range of one another, it would seem that input of configuration data to the user interface38would need to be performed within the space10while configuration occurs in the controller100outside the space. This situation would require trips back and forth to confirm that the controller100is properly set-up and activates the selected system component. The present controller100and user interface38address these and other issues, as explained below.

Referring toFIG. 2, a user interface38is shown that includes a sensor configured to sense temperature. The user interface38may, for example, be a thermostat, which provides activation signals for climate control apparatus. A first portion of the user interface38includes a display40and input controls42,44for enabling selection of configuration setting parameters. The user interface38is connectable to a sub-base portion46installed in a space10. The connectors48enable connection of two wires50and52for providing power via a24volt alternating current transformer to terminals labeled “R” and “C,” and connection of two wires54and56for providing communication (between the controller100and user interface38) to terminals labeled “1” and “2.” The user interface38is connected to the sub-base portion46in a manner such that pins in the user-interface mate with connections “R” and “C” for providing power, and with connections “1” and “2” that provide for communication.

Referring toFIG. 3, a first embodiment of a controller100includes output connections “1” and “2” for wired connection to the sub-base portion46of the user interface38(as inFIG. 2). A transformer34also provides “R” and “C” power connections to the sub-base portion46(shown inFIG. 2). The controller100includes a plurality of relays104, and may generally comprise a relay panel. The controller100includes a plurality of connectors106associated with the relays104for enabling connection to various climate control apparatus. For example, the controller100may send a signal to a connector “G” and an associated wire for enabling connection of a voltage to an indoor air circulation unit12, and may send a signal to a connector “Y” and wire for enabling connection of a voltage to a compressor22of an air conditioner unit20, to establish cooling operation. The controller100may send a signal to a “W” connector and wire for enabling connection of a voltage to a gas-fired heating unit14, or to connector “W/E” for activating electric heating elements16to establish heating operation. The controller100may send a signal to an “O/B” connector for a reversing valve26for utilizing the air conditioning compressor22in a heat pump mode, to provide for heating operation in combination with or in place of a gas or electric heating unit. In some climate control systems, electric heating elements16may be activated with the heat pump as a back up, for situations when the heat pump does not provide adequate heat (when sub-freezing outside temperatures limit the heat pump). The controller100is configurable to operate each of these climate control apparatus. As such, the controller100requires input of configuration setting parameters in order to know which connections to command/signal for activating the appropriate apparatus.

As shown inFIG. 1, the user interface38and controller100are connected to each other by at least a pair of wires that enable communication therebetween, where the user interface38may be connected via existing wires within the premises for a previous thermostat. While the controller100is mountable to a climate control unit segregated from the space10and user interface38is within the space10(such that the two devices are not co-located), configuration setting parameters may be input via the user interface38without requiring trips back and forth to test the system and confirm that settings have been correctly entered, as explained below.

Referring toFIG. 4, a communication means is shown for use in configuring the controller100inFIG. 3. The communication means may be a connection tool150with connectors152,154, which are releasably connectable to the user interface38(inFIG. 2) and coupled to a wiring harness160that is connectable to the input means102(inFIG. 3), for enabling communication from the user interface38to the controller100. In one embodiment, the connection tool150includes two connectors152,154for connecting to the first and second communication connections “1” and “2” of the user interface38, and may further include two connectors156,158that connect or mate with connections “R” and “C” for providing power to the user interface38(inFIG. 2). The input means102preferably comprises an RJ-11 receptacle, and the wiring harness160preferably includes an RJ-11 plug connector162that connects to the RJ-11 receptacle of the controller100. The connection tool150may comprise a suedo-sub-base164, which mates with the user interface38in a manner such that the connectors152,154are connectable to the user interface38(e.g., connections “1” and “2”) when the user interface38is mated to the connection tool150.

Accordingly, the user interface38(or thermostat) may be removed from the sub-base portion46installed in the space10, and taken to the location of the controller100where the user interface38is connected to a connection tool150(having connectors152,154releasably connectable to the user interface38and coupled to a wiring harness160that connects to the controller100), to enable communication from the user interface38to the controller100. Once connected, the user interface38display40displays selectable setting parameters for configuring the controller100, and user input controls42,44enable selection of the displayed selectable setting parameters.

The user interface38comprises input controls42,44for selection from the display40of one or more displayed selectable setting parameters, which are listed in the Table shown inFIG. 5. The display of one or more selectable setting parameters enable a user or installer to set-up the controller100. For example, the controller100may be set-up for a configuration in which there is no air conditioner unit20(e.g., option AC0). The controller100may be set-up for a configuration in which the air conditioner/compressor22has a single speed or capacity (e.g., option AC1) as shown inFIG. 1, or may also be set-up for a configuration in which the compressor22has two speeds or capacity levels (e.g., option AC2) as shown inFIG. 3where compressor22has a Y and Y2 connection. With option AC2, the controller100is configured to provide different activation signals for activating the compressor in a full-capacity mode and a less than full capacity mode (e.g., “Y” and “Y2”). Similarly, the controller100may be set up to operate a compressor22in a single capacity heat pump mode (e.g., option HP1) or a dual capacity heat pump mode (e.g., option HP2).

The various controller embodiments may be set-up as shown inFIG. 5for a configuration (e.g., option GA1) in which an indoor air circulation unit12operates with a single capacity gas-fired heating unit14as inFIG. 1, or optionally with a dual capacity gas-fired heating unit (e.g., option GA2). The controller may be set-up for a configuration in which the indoor air circulation unit12also operates with a single capacity heater using electric heating elements16(e.g., option EL1) or optionally a dual capacity heater using electric heating elements16(e.g., option EL2). The controller100can also be configured (e.g., option FAN) to operate indoor air circulation unit12only as a fan during heat-pump mode, for example.

Accordingly, in one preferred embodiment, the controller100ofFIG. 3may be set-up by using the user interface38to select option “AC1” for a typical air conditioning system and option “GA1” for a gas-fired heating unit14. In yet another embodiment, the controller100may be set-up using the user interface38to select option “HP1” for an air conditioning system and heat pump system, and option “FAN” for operation of the indoor air circulation unit12simultaneous with the compressor22of the heat pump. Alternatively, the controller100may be set-up for “dual heating systems” by selection of option “HP1” for an air conditioning system and heat pump system, and option “GA1” for a gas-fired heating unit14. The criticality of proper configuration of the controller100for such systems is explained below.

In situations of dual heating systems, the heat-pump supplies heat to the space10during above-freezing outside temperature conditions, and the gas-fired heating unit14may supply additional heat to the space10during sub-freezing outside temperatures (when sub-freezing temperatures limit heating by the heat pump). Accordingly, where the controller100is configured for “HP1” and “GA1” setting parameters, the controller100may generate an activation signal for turning on the gas-fired heating unit14(via “W” as shown inFIG. 3), an activation signal for turning on the compressor22(via “Y” as shown inFIG. 3), and an activation signal for turning on the reversing valve26(via “O” inFIG. 3).

The importance of proper set-up and configuration is illustrated by the B or O heat pump terminal set-up options. Depending on the type of heat pump, the controller100is configured by entering via the user interface38a selection for the “O/B” setting, as to whether the heat pump reversing valve26is switched “on” for cooling or “on” for heating operation. For example, with some heat pumps manufactured by Rheem, the “O/B” setting parameter for controller100must be configured to switch “on” the reversing valve26to provide heating operation, as in the above described configuration setting. However, with some heat pumps manufactured by Trane, an “O/B” setting for switching “on” the reversing valve26will provide cooling operation (with off being heat operation). In the situation of dual heating systems where the gas-fired heating unit14may be operated along with the heat-pump, an improper “O/B” setting can cause operation of the heat pump in cool mode in conflict with operation of the gas-fired heating unit14(e.g., will cause simultaneous operation of both the air conditioner unit20and the gas-fired heating unit14).

The above miss-configuration could result in simultaneous operation of the air conditioner unit20and conventional gas-fired heating unit14. If the controller100were inadvertently configured to turn on both the air conditioner unit20and gas-fired heating unit14at the same time, an installer who is within the space10might not be able to detect this operation within a short time, to prevent potential damage to the components of the air conditioner unit20. By using the user interface38and connection tool150for selecting configuration setting parameters at the location of the controller100and climate control apparatus, the installer can select one or more configuration setting parameters and observe the operation of the climate control apparatus to test and confirm that settings have been correctly entered, without having to make back and forth trips from the space10to the climate control apparatus segregated from the space. Accordingly, the user interface38and connection tool150provide a novel approach for selecting one or more selectable configuration setting parameters of a configurable controller100at the location of the controller100, to test and confirm that the proper setting parameters have been selected.

According to another aspect of the present disclosure, another embodiment of a controller200provides a visual indicator, such as a light emitting diode for example, for indicating the selection of a setting parameter via user interface38to provide for confirmation of the selected setting parameter. As shown inFIG. 6, the controller200includes an input means202for receiving communication of a selection of at least one setting parameter, and a plurality of visual indicators270. The indicators270indicate a selection (via the user interface38) of at least one configuration setting parameter of the controller200.

The selection of at least one configuration setting parameter is made through the user interface38, by user input controls42,44for selecting from a plurality of displayed selectable setting parameters, and communicated to via connection tool150to the controller200, which illuminates or activates at least one visual indicator270for indicating a selection of at least one selectable setting parameter by the user interface38, where the visual indicator270may be an LED or elements of an LCD display that may be activated. Specifically, the controller200illuminates or activates a corresponding indicator on the controller200that corresponds with a given selection made via the user interface38. For example, where the user interface38is used in selection of a configuration for a single capacity gas-fired heating unit14(e.g., option W1) the controller100is configured to receive communication of the selection and activate a “W” visual indicator272for indicating selection of the selectable setting parameter “W1” by the user interface38. Where the user interface38is used in selection of a configuration in which the air conditioner unit20has a single speed or capacity (e.g., option AC1), the controller200is configured to receive communication of the selection and activate a “Y” visual indicator274for indicating selection of the selectable setting parameter “AC1” by the user interface38. Similarly, where the user interface38enters a selection of a configuration of a two speed/capacity air conditioner (option AC2), the controller200is configured to receive communication of the selection and activate a “Y2” visual indicator276for indicating selection of setting parameter “AC2.” Where the user interface38enters the selection of a configuration of a heat pump with a reversing valve26(option O), the controller200is configured to receive communication of the selection and activate an “O/B” visual indicator278for indicating selection of setting parameter “O.” Accordingly, the controller200receives communication of a selection and activates a visual indicator that corresponds with the selection to provide for confirmation.

The controller200inFIG. 6is not only configured to control activation of the visual indicators270corresponding to a selection, but also to control the color of the indicator to correspond with the given configuration. For example, with regard to selection of a heating system configuration via the user interface38, the controller200will respond to selection of a gas-fired heating unit14(as inFIG. 1) by activating the “W” visual indicator272in a manner to cause the “W” visual indicator272to glow an amber color. Alternatively, the controller200will respond to selection of a heater using electric heating elements16(as inFIG. 1) by activating the “W” visual indicator272in a manner to cause the “W” visual indicator272to glow a green color. This can be accomplished by providing different voltage inputs to a multi-color LED, for example, or by controlling elements of a color LCD display. Accordingly, not only does the “W” visual indicator272provide an immediate indication of selection of a heating system configuration setting parameter, the “W” visual indicator272also provides an indication of the system type that the controller200is being configured for. The controller200may also include a cover280with a tab282located thereon, as shown inFIG. 7. The tab282engages a switch or electrical component to cause the controller200to prevent the visual indicators270from being activated when the cover280is installed, to prevent nuisance concerns with the visual indicators. However, the controller200may be configured to permit display of the visual indicators when the cover280installed, by removal of a portion of the tab282(e.g., breaking off the end).

Accordingly, one embodiment of a configurable system is provided for controlling various types of climate control apparatus that provided visual confirmation of configuration settings. The system includes a controller200(shown inFIG. 6) mountable to a climate control apparatus (e.g., indoor air circulation unit12shown inFIG. 1that is segregated from the space10to be conditioned). The controller200has a plurality of selectable setting parameters for configuring the controller to control operation of at least one of a plurality of climate control apparatus, and a plurality of visual indicators270, each of which provide an indication of the selection of a selectable setting parameter. The controller200also has an input means202for receiving communication of information indicating a selection of at least one of the selectable setting parameters. The system includes a user interface (e.g. user interface38inFIG. 2) adapted for installation within a space10(shown inFIG. 1). The user interface38has a display40configured to display the selectable setting parameters, and user-input controls42,44for enabling selection of at least one displayed selectable setting parameter, as shown inFIG. 2. A communication means (inFIG. 4) provides for communicating information from the user interface38(inFIG. 2) to the controller200shown inFIG. 6that is indicative of the selection of at least one selectable setting parameter. The controller200is configured to activate at least one visual indicator270for indicating selection of a selectable setting parameter by the user interface38via the communication means. The controller200may further include a cover280having a tab282on an interior portion of the cover280, wherein the tab282causes the controller200to prevent activation of the visible indicators270when the cover280is installed on the controller200.

In yet another aspect of the present disclosure, the various controller embodiments are further configured to control a humidity control. For example, the controller200shown inFIG. 6is configured to control a switch to establish a connection at284for applying a voltage via controller200for activating a humidity control32(shown inFIG. 1) at the same time as the indoor air circulation unit12(shown inFIG. 1). Alternatively, where the humidity control32is self-powered, the controller200may close a switch to establish a connection (at286) for activating a self-powered humidity control32. Accordingly, the controller200is configured to activate a self-powered humidifier (or dehumidifier) or to pass through a24volt alternating current to a non self-powered humidifier (or dehumidifier). The controller200is further configurable to operate self-powered or non self-powered humidity controls with either a single fixed speed indoor air circulation unit12, or a variable speed indoor air circulation unit12. The HM and DHM symbols shown inFIG. 6correspond to wiring terminals284and286on the controller200.

The selection of a setting parameter for HM or HM2, or DHM or DHM2, is made using a selector component, such as a 2 position slide switch288located on the controller200. When the switch is slid to the “dry” position, the choice is made for a self powered device, and the controller200simply closes a connection for passing power through the terminal and/or appropriate relay on the controller200for activating a self-powered humidity control32as inFIG. 1. When the 2 position slide switch288is slid to the other position, the controller200uses the 24 volt alternating current from a system transformer (e.g.,34inFIG. 3) to operate the non self-powered humidifier or dehumidifier. In addition the controller200can operate the humidifier or dehumidifier independent of a call for heat or cool (e.g., not simultaneous with operation of a heating or air conditioning system). Thus, when a sensed relative humidity is detected by a user interface38(inFIG. 2) or a thermostat, for example, the indoor air circulation unit12inFIG. 1is turned on along with the appropriate humidity control32(e.g., humidifier or dehumidifier) and operated until the requested relative humidity set point is reached. If the controller200is not configured for operation in independent mode, then the humidity control32only operates during a call for heat or cool. This provides the novel feature of a controller200that is configurable to utilize detection of sensed relative humidity by the user interface38(or thermostat) to control an independent humidifier or dehumidifier without requiring the use of a separate thermostat for the independent humidifier or dehumidifier. Accordingly, a system is provided for controlling various climate control apparatus for conditioning a space that comprises a controller mountable to a climate control apparatus segregated from the space, which has a plurality of selectable setting parameters for configuring the controller to control operation of at least one of a plurality of climate control apparatus. The controller further includes an input means for receiving communication of information that is indicative of a selection of at least one selectable setting parameter. Based on the selection of at least one selectable setting parameter, the controller is configured to selectively operate the humidity control device at times when the controller has not activated a heating or air conditioning unit, or to selectively operate the humidity control device at times when the controller activates a heating or air conditioning unit. The various embodiments of a controller may be configured to cause the visual indicators to blink to provide a notice of an inappropriate set-up or configuration. Thus, controller100is further configurable to provide notice to an installer of the improper set-up.