BUILDING CONTROLLER WITH WIRING TERMINALS PROGRAMMABLE BETWEEN AN INPUT WIRING TERMINAL TYPE, AN OUTPUT WIRING TERMINAL TYPE, AND A COMMUNICATION WIRING TERMINAL TYPE

A building controller includes a housing and a plurality of wiring terminals that are secured relative to the housing and are physically accessible from outside of the housing. A controller is housed by the housing and is operatively coupled to the plurality of wiring terminals. The controller is field programmable to set each of two or more of the plurality of wiring terminals to a particular one of a plurality of wiring terminal types including an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type where the communication wiring terminal type operates in accordance with a predetermined communication protocol.

TECHNICAL FIELD

The present disclosure relates to building controllers, and more particularly, to building controllers having programmable wiring terminals.

BACKGROUND

Many controllers, including building controllers, are produced having fixed communication ports and fixed I/O control terminals. If all of the communication ports or I/O control terminals are used up, and the user wants the controller to be part of an additional network, or wants additional I/O control terminals, the user is required to add additional equipment such as an additional building controller. This can make the installation process expensive and complicated. In some cases, a building controller may have unused communication ports even though all of the I/O control terminals are used. A building controller may have unused I/O control terminals even though all of the communication ports have been used. What would be desirable is a building controller that allows a user to use unused communication ports as I/O control terminals, and/or to use unused I/O control terminals as communication ports. What would be desirable is a building controller having a plurality of wiring terminals that can be programmed to function as either communication ports or as I/O control terminals, depending on the need.

SUMMARY

This disclosure relates to building controllers, and more particularly, to building controllers having programmable wiring terminals. An example may be found in a building controller that includes a housing and a plurality of wiring terminals that are secured relative to the housing and are physically accessible from outside of the housing. A controller is housed by the housing and is operatively coupled to the plurality of wiring terminals. The controller is field programmable to set each of two or more of the plurality of wiring terminals to a particular one of a plurality of wiring terminal types including an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type where the communication wiring terminal type is configured to operate in accordance with a predetermined communication protocol.

Another example may be found in a method for programming a building controller. The example method includes displaying on a display a representation of each of a plurality of wiring terminals of the building controller. A wiring terminal type selector for each of two or more of the plurality of wiring terminals of the building controller is displayed on the display. At least some of the wiring terminal type selectors allow a user to select between an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type for the corresponding wiring terminal of the building controller. A functionality of each of the two or more of the plurality of wiring terminals of the building controller is then programmed based on selections made by the user via the wiring terminal type selectors.

Another example may be found in a method that includes setting each of a plurality of wiring terminals of a building controller to a particular one of a plurality of wiring terminal types including an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type. Two or more of the plurality of wiring terminals are set to the communication wiring terminal type and are associated with a first predetermined communication protocol, and two or more of the plurality of wiring terminals are set to the communication wiring terminal type and are associated with a second predetermined communication protocol different from the first predetermined communication protocol. The example method includes receiving one or more first communication messages via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over a first communication bus and translating the one or more first communication messages received over the first communication bus to the second predetermined communication protocol, resulting in one or more first translated messages. The one or more first translated messages may be routed to and communicated over a second communication bus via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol.

The preceding summary is provided to facilitate an understanding of some of the features of the present disclosure and is not intended to be a full description. A full appreciation of the disclosure can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

DESCRIPTION

The following description should be read with reference to the drawings wherein like reference numerals indicate like elements. The drawings, which are not necessarily to scale, are not intended to limit the scope of the disclosure. In some of the figures, elements not believed necessary to an understanding of relationships among illustrated components may have been omitted for clarity.

FIG.1is a schematic block diagram of an illustrative building control system10. The illustrative building control system10includes a first network12and a second network14. While the first network12is labeled as being a BACnet network, and the second network14is labeled as being a Modbus network, this is merely illustrative. Each of the first network12, the second network14and any additional networks (not shown) may be selected from any of a variety of communication protocols such as but not limited to BACnet, Modbus, UART, RS485, Sylk, C-bus, M-Bus, CAN Bus, KNX, LonWorks, Novar Net, and Dali, for example. Building controllers that communicate via the communication protocol implemented by the first network12may be operably coupled to and communicate with the first network12. Building controllers that communicate via the communication protocol implemented by the second network14may be operably coupled to and communicate with the second network14. Some building controllers may be configured to translate between different communication protocols, and thus may be operably coupled to and communicate with the first network12and the second network14.

As shown, a total of three building controllers16, individually labeled as16a,16band16c, are operably coupled to the first network12. It will be appreciated that each of the building controllers16have a number of wiring terminals that are labeled1through24, with the wiring terminals along the top of each building controller16sequentially numbered01through12in a first direction and the wiring terminals along the bottom of each building controller16sequentially numbered13through24in a second, opposing direction. It will be appreciated that this is merely illustrative, as each of the building controllers16may have any number of wiring terminals, which may be arranged and/or labeled in any suitable fashion.

In some cases, the specific wiring terminals designated for communicating with a particular network such as the first network12or the second network14may be different for each of the building controllers16. The specific wiring terminals designated for communicating with the first network12and/or the second network14may be uniquely programmed for each of the building controllers16. As an example, the building controller16auses wiring terminals01and02to communicate with the first network12. The building controller16buses wiring terminals03and04to communicate with the first network12and uses wiring terminals14and15to communicate with the second network14. The building controller16cuses wiring terminals04and05to communicate with the first network12and uses wiring terminals13and14to communicate with the second network14. As shown, the building controller16aonly communicates with the first network12. The building controller16bcommunicates with the first network12and with the second network14. The building controller16ccommunicates with the first network12and with the second network14.

In some cases, the building controller16band/or the building controller16care configured to translate between the communication protocol implemented by the first network12and the communication protocol implemented by the second network14. In some cases, the building controller16band/or the building controller16care configured to communicate only using the communication protocol implemented by the first network12, but can “route” or “pass through” communications that use the communication protocol implemented by the second network14, or vice versa. In some cases, the building controllers16may perform a router function, if desired. While only two networks12,14are shown, each implementing a different communication protocol, some building controllers16,18may be configured communicate, translate and/or route communication messages over two, three or more different communication protocols, with each communication protocol implemented on a different network.

As shown, a total of three building controllers18, individually labeled as18a,18band18c, are operably coupled to the second network14. It will be appreciated that each of the building controllers18have a number of wiring terminals that are labeled1through24, with the wiring terminals along the top of each building controller18sequentially numbered01through12in a first direction and the wiring terminals along the bottom of each building controller18sequentially numbered13through24in a second, opposing direction. It will be appreciated that this is merely illustrative, as each of the building controllers18may have any number of wiring terminals, which may be arranged and/or labeled in any suitable fashion.

In some cases, the specific wiring terminals designated for communicating with a particular network such as the first network12or the second network14may be different for each of the building controllers18. The specific wiring terminals designated for communicating with the first network12and/or the second network14may be uniquely programmed for each of the building controllers18. As an example, the building controller18auses wiring terminals04and05to communicate with the second network14. The building controller18buses wiring terminals01and02to communicate with the second network14. The building controller18cuses wiring terminals07and08to communicate with the second network14.

In an example operation, building controller16bmay communicate with building controller16c,18a,18band/or18cover the second network14, and may communicate with building controller16band16cover the first network14. Each of the building controllers16and18may be configured to control operation of one or more features of a building control system. For example, some of the building controllers16and18may control operation of various components of a Heating, Ventilating and Air Conditioning (HVAC) system of a building. Some of the building controllers16and18may control operation of various components of a building lighting system. Some of the building controllers16and18may control operation of various components of a building security system. Some of the building controllers16and18may control operation of various components of a building fire system. These are just examples.

In one particular example, building controller18amay control operation of a building fire system, and building controller16bmay control operation of a building Heating, Ventilating and Air Conditioning (HVAC) system. If a smoke sensor operatively coupled to an input terminal (e.g. terminal23programmed as an input terminal) of the building controller18aindicates smoke in the building, the building controller18amay sound an alarm by activating an output terminal (e.g. terminal14programmed as an output terminal) of the building controller18athat is operatively coupled to a sound producing component in the building. The building controller18amay also send a smoke alarm message onto the second network14. The building controller16bmay receive the smoke alarm message via the second network14. In response, the building controller16bmay close an air damper of the HVAC system to help slow the spread of smoke throughout the building by activating an output terminal (e.g. terminal19programmed as an output terminal) of the building controller16bthat is operatively coupled to the damper. This is just one example.

FIG.2is a schematic block diagram of an illustrative building controller20that may be considered as being an example of one of the building controllers16and18. The illustrative building controller20includes a housing22. A plurality of wiring terminals24, individually labeled as24a,24b,24cthrough24nare secured relative to the housing22and are physically accessible from outside of the housing22such that an installer is able to connect wires to any of the wiring terminals24even after the building controller20has been mounted to a wall or within an electrical panel. In some cases, the building controller20may be configured to be mounted to a DIN rail that is either wall-mounted or panel-mounted, for example.

The illustrative building controller20includes a controller26that is housed by the housing22and is operably coupled to the plurality of wiring terminals24. In some cases, the controller26is field programmable to set each of two or more of the plurality of wiring terminals24to a particular one of a plurality of wiring terminal types including an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type where the communication wiring terminal type operates in accordance with a predetermined communication protocol. The predetermined communication protocol may be field programmable to one of two or more different communication protocols.

In some cases, the input wiring terminal type is set when the corresponding wiring terminal24is to receive an input signal from, for example, a remote sensor. The output wiring terminal type may be set when the corresponding wiring terminal24is to provide a control signal to a remote actuator or the like. The communication wiring terminal type may be set when the corresponding wiring terminal24is to be used to communicate with a remote device using the predetermined communication protocol.

In some instances, a first one of the plurality of wiring terminals24has the input wiring terminal type or the output wiring terminal type as a default setting, and the controller26is field programmable to change the first one of the plurality of wiring terminals24to the communication wiring terminal type. A first one of the plurality of wiring terminals24may have the communication wiring terminal type by default, and the controller26is field programmable to change the first one of the plurality of wiring terminals24to the input wiring terminal type or the output wiring terminal type.

In some cases, the controller26includes a printed circuit board28. The printed circuit board28may include a number of I/O terminal circuits30, individually labeled as30a,30b,30cand through30n, that are mounted to the printed circuit board28. In the example shown, each of the number of I/O terminal circuits30are operatively coupled to a corresponding one of the plurality of wiring terminals24. That is, there may be a separate I/O terminal circuit30dedicated to each of the plurality of wiring terminals24. In some cases, each of the plurality of I/O terminal circuits30include an I/O device separately packaged and mounted to the printed circuit board28, and one or more external devices that are external to the I/O device also mounted to the printed circuit board28. In some instances, each of the I/O devices include a number of device pins including one or more device input pins, one or more device output pins, and two or more device communication pins.

When a first one of the plurality of wiring terminals24is set to be of the input wiring terminal type, the corresponding I/O device is configured to operatively couple the first one of the plurality of wiring terminals24to one of the one or more device input pins of the I/O device. When the first one of the plurality of wiring terminals24is set to be of the output wiring terminal type, the corresponding I/O device is configured to operatively couple the first one of the plurality of wiring terminals24to one of the one or more device output pins of the I/O device. When the first one of the plurality of wiring terminals24is set to be of the communication wiring terminal type, the corresponding I/O device is configured to operatively couple the first one of the plurality of wiring terminals24to one of the two or more device communication pins of the I/O device. It will be appreciated that example I/O device pins are visible inFIGS.3and4. In some cases, the I/O device that corresponds to the first one of the plurality of wiring terminals24may be field programmable to set the first one of the plurality of wiring terminals24to the particular one of the plurality of wiring terminal types using commands sent to the I/O device via one or more of the device communication pins of the I/O device.

FIG.3is a schematic block diagram of an I/O portion32of an illustrative building controller usable in the illustrative building control system10ofFIG.1. In some cases, the I/O portion32shown inFIG.3may be representative of the I/O terminal circuits30and controller26supporting three wiring terminals24of the building controller20.

In the example shown, the I/O portion32includes a microcontroller34. Universal Input/Output (UIO) chips36, individually labeled as36a,36band36c, are each operably coupled to a single wiring terminal38, individually labeled as38a,38band38c. This is merely illustrative, as the I/O portion32will in many cases have a greater number of UIO chips36and corresponding wiring terminals38. The UIO chips36may be considered as being an example of the I/O devices referenced with respect toFIG.2as being part of the I/O terminal circuits30. Each of the UIO chips36are operably coupled to a number of wiring leads or conductive traces on a circuit board, connecting to the microcontroller34. These wiring leads or conductive traces include communication paths such as UART1-RX and UART1-TX, SCL and SDA, along with power paths GND and VCC. These wiring leads or conductive traces also include a 12C bus, a UART bus and a number of wiring paths for Chip Select (CS), General Purpose Input/Output (GPIO)-Digital and GPIO-Analog (PWM).

FIG.4is a schematic block diagram of a UIO Application Specific Integrated Circuit (ASIC) Chip suitable for use with the illustrative building controller ofFIG.3, and in the example shown represents one of the UIO chips36ofFIG.3. The UIO ASIC chip can be programmed using the UART (UART Tx, UART Rx), I2C (SCL, SDA) and/or the SPI (SCK, SDI, SDO) interface. The terminal pin38(wiring terminal) is exposed to the outside of the housing, such that a user can attach a wire to it. The UIO ASIC chip ofFIG.4can be seen as including a number of pins40, including a UART Tx pin40a, a UART Rx pin40b, a GPIO-digital pin40c, a GPIO-analog (PWM) pin40d, a reset pin40eand a Chip select pin40f. The UIO ASIC chip also includes a number of pins42, including an SCL pin42a, an SDA pin42b, an SCK pin42csupporting the SPI interface protocol, and an SDI pin42dand an SDO pin42esupporting the I2C interface protocol. The illustrative UIO ASIC chip also includes power pins44, including a VCC pin44aand a GND pin44b. The voltage applied to the VCC pin44amay be at 3.3 volts, 6 volts, 9 volts, 12 volts and/or any other suitable voltage. It is contemplated that the voltage can be stepped up or down by the additional components46operatively coupled to the UIO ASIC chip, depending on the function of the corresponding terminal pin38.

The UIO ASIC chip may interface with one or more additional components46, such as but not limited to line drivers, transceivers, inductors, capacitors, small transformers and optical isolation components, for example. If the terminal pin38is acting like any of DI (digital input), DO (digital output), AI (analog input) or AO (analog output), it will be driven based on either the GPIO-Digital40cpin or the GPIO-Analog (PWM) pin40d. If the terminal pin38is programmed to be a communication terminal, the data will primarily be driven from one of the UART/I2C/SPI pins. The reset pin40ebrings the UIO ASIC chip back to a default configuration.

FIG.5shows an illustrative tool50for programming a building controller such as any of the building controllers16,18,20and32. In some cases, the tool50may be a standalone tool that may be temporarily wired to the building controllers16,18,20and32, or connected to one of the building controllers16,18,20and32via a building network. In some cases, the tool50may represent a functionality that is built into one of the building controllers16,18,20and32. The illustrative tool50includes a menu52along a left side of a display. As shown, the Custom Wiring icon is highlighted or bolded, indicating that it has been selected. As a result, the tool50displays a wiring plan54that shows each of the available wiring terminals of the building controller. For some of the wiring terminals, the wiring plan54also shows a pull-down menu56that allows selection of a different use for a particular wiring terminal, or perhaps allows assigning a use to a pin that is currently unassigned. Some wiring terminals are not programmable, or their programming is conflicted out by the selection made for one or more other terminals, and hence do not include a pull-down menu56for that particular wiring terminal.

For some of the terminals, the pull-down menu56may allow a user to set the corresponding terminal pin to an input wiring terminal type, an output wiring terminal type or a communication wiring terminal type. In some cases, the pull-down menu56may allow the user to set the corresponding pin to an input wiring terminal type (digital), an input wiring terminal type (analog—PWM), an output wiring terminal type (digital), an output wiring terminal type (analog—PWM), and/or a communication wiring terminal with a corresponding communication protocol (e.g. BACnet, Modbus, UART, RS485, Sylk, C-bus, M-Bus, CAN Bus, KNX, LonWorks, Novar Net, and Dali, for example). These are just examples.

The illustrative tool50includes a Validate button58, a Terminal Overlay Diagram button60and a Wiring Diagram button62. The Validate button58may be selected to instruct the tool50to validate the assigned functions to ensure that the controller can operate with those assigned functions. The Terminal Overlay Diagram button60may be selected to instruct the tool50to display wiring labels that can be printed out and pasted onto the building controller housing to label what each wiring terminal is for. The Wiring Diagram button62may be selected to instruct the tool50to print out a wiring diagram.

FIG.6shows an example of a wiring diagram64that may be displayed. The wiring diagram64includes a representation66that shows all of the wiring terminals as well as the devices68that are physically wired to particular wiring terminals of the building controller. As shown, several digital output pins DO-B3and DO-B2are connected to second stage cooling and first stage cooling, respectively. A digital output pin DO-B1is connected to a fan. Heating is connected to several other digital output pins. First stage heating is connected to a pin DO-A1while second stage heating is connected to a pin DO-S2. The cooling stages and fan are also connected to a Communication (COM) B pin while the heating stages are connected to a COM A pin. An economizer is connected to an analog pin AO-1and a COM pin. Other devices, if connected, would be shown in a similar fashion.

FIG.7is a flow diagram showing an illustrative method70for programming a building controller (such as any of the building controllers16,18,20and32). The illustrative method70includes displaying on a display a representation of each of a plurality of wiring terminals of the building controller, as indicated at block72. A wiring terminal type selector for each of two or more of the plurality of wiring terminals of the building controller is displayed on the display. At least some of the wiring terminal type selectors allow a user to select between an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type for the corresponding wiring terminal, as indicated at block74. A functionality of each of the two or more of the plurality of wiring terminals of the building controller is programmed based on selections made by the user via the wiring terminal type selectors, as indicated at block76.

In some cases, the illustrative method70may include validating that the building controller can accommodate the selections made by the user via the wiring terminal type selectors before programming the functionality of each of the two or more of the plurality of wiring terminals of the building controller, as indicated at block78. In some cases, programming each of the two or more of the plurality of wiring terminals of the building controller may include programming each of two or more I/O terminal circuits of the building controller, wherein each of the two or more I/O terminal circuits of the building controller is associated with a corresponding one of the two or more of the plurality of wiring terminals of the building controller.

FIG.8is a flow diagram showing an illustrative method80for programming a building controller (such as any of the building controllers16,18,20and32). The illustrative method80includes displaying on a display a representation of each of a plurality of wiring terminals of the building controller, as indicated at block82. A wiring terminal type selector for each of two or more of the plurality of wiring terminals of the building controller is displayed on the display, at least some of the wiring terminal type selectors allowing a user to select between an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type for the corresponding wiring terminal, as indicated at block84. A functionality of each of the two or more of the plurality of wiring terminals of the building controller is programmed based on selections made by the user via the wiring terminal type selectors, as indicated at block86.

In some cases, and for those wiring terminals of the building controller that the user selected the communication wiring terminal type, if any, the illustrative method80may include programming the corresponding wiring terminals to operate in accordance with a predetermined communication protocol, as indicated at block88. In some cases, the illustrative method80may include selecting the predetermined communication protocol from two or more different predetermined communication protocols, as indicated at block90. The two or more different predetermined communication protocols may include two or more of BACnet, Modbus, UART, RS485, Sylk, C-bus, M-Bus, CAN Bus, KNX, LonWorks, Novar Net, and Dali, for example.

FIG.9is a flow diagram showing an illustrative method92that includes setting each of a plurality of wiring terminals of a building controller to a particular one of a plurality of wiring terminal types including an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type, as indicated at block94. Two or more of the plurality of wiring terminals are set to the communication wiring terminal type and are associated with a first predetermined communication protocol, and two or more of the plurality of wiring terminals are set to the communication wiring terminal type and are associated with a second predetermined communication protocol different from the first predetermined communication protocol, as indicated at block96.

One or more first communication messages are received via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over a first communication bus, as indicated at block98. The one or more first communication messages received over the first communication bus are translated to the second predetermined communication protocol, resulting in one or more first translated messages, as indicated at block100. The one or more first translated messages are routed via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol over a second communication bus, as indicated at block102.

FIG.10is a flow diagram showing an illustrative method104that includes receiving one or more first communication messages via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over a first communication bus, as indicated at block106. The one or more first communication messages received over the first communication bus are translated to the second predetermined communication protocol, resulting in one or more first translated messages, as indicated at block108. The one or more first translated messages are routed via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol over a second communication bus, as indicated at block110. In some cases, the method104includes sending one or more communication messages via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over the first communication bus, as indicated at block112. The method104may include receiving one or more communication messages via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol over the second communication bus, as indicated at block114.

FIG.11is a flow diagram showing an illustrative method116that includes receiving one or more first communication messages via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over a first communication bus, as indicated at block118. The one or more first communication messages received over the first communication bus are translated to the second predetermined communication protocol, resulting in one or more first translated messages, as indicated at block120. The one or more first translated messages are routed via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol over a second communication bus, as indicated at block122.

In some cases, the illustrative method116may include receiving one or more second communication messages via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol over the second communication bus, as indicated at block124. The one or more second communication messages received over the second communication bus are translated to the first predetermined communication protocol, resulting in one or more second translated messages, as indicated at block126. The one or more second translated messages are routed via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over the first communication bus, as indicated at block128.

FIG.12is a flow diagram showing an illustrative method130that includes setting each of a plurality of wiring terminals of a building controller to a particular one of a plurality of wiring terminal types including an input wiring terminal type, an output wiring terminal type, and a communication wiring terminal type, as indicated at block132. One or more first communication messages are received via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over a first communication bus, as indicated at block134. The one or more first communication messages received over the first communication bus may be translated to the second predetermined communication protocol, resulting in one or more first translated messages, as indicated at block136. The one or more first translated messages are routed via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol over a second communication bus, as indicated at block138.

In some cases, in response to receiving one or more first communication messages via the two or more of the plurality of wiring terminals associated with the first predetermined communication protocol over the first communication bus, the building controller need not translate the one or more message to the second predetermined communication protocol. Instead, the building controller may interpret the one or more first communication messages and perform an operation based at least in part on the one or more first communication messages and logic of the building controller. For example, the building controller may activate or de-activate one or more of its input wiring terminals and/or output wiring terminals in response to receiving one or more first communication messages. In some cases, the building controller may assembly and send one or more second communication messages via the two or more of the plurality of wiring terminals associated with the second predetermined communication protocol over the second communication bus. The second communication messages may not be translated versions of the one or more first communication messages, but rather may be generated by the building controller based on internal logic of the building controller. In some cases, the second communication messages that are generated by the building controller may be in response to one or more of the first communication messages and based on logic of the building controller.

In some cases, the illustrative method130may include setting each of one or more of the plurality of wiring terminals that are set to the communication wiring terminal type to the input wiring terminal type or the output wiring terminal type, as indicated at block140. The illustrative method130may further include setting one or more of the plurality of wiring terminals that are set to the input wiring terminal type or the output wiring terminal type to the communication wiring terminal type, as indicated at block142.