System powered power supply using dual transformer HVAC systems

Abstract: A power supply to supply power to a secondary system receives power from a plurality of primary systems. The power supply has a first rectifier which supplies power to the secondary system from a first primary system and at least one isolated rectifier which is connected to a primary system other than the first primary system. Due to the characteristic of the isolated rectifier, it is not possible to connect the first primary system out of phase with the primary system other than the first primary system, thereby eliminating unsafe voltages.

Description: FIELD OF THE INVENTION This invention relates to low-voltage space thermostats which control operation of single-stage heating and cooling systems. BACKGROUND OF THE INVENTION Typically, in a single-stage heating and cooling system, the heating system includes a low-voltage 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 contacts control energizing of the compressor, and the circulation system includes a fan relay having a low-voltage coil and high-voltage contacts, which contacts 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 or by two separate transformers. If the heating and cooling system is installed as a complete unit, generally a single transformer is provided. Such a single transformer has the required volt-ampere output to operate all the low-voltage operated devices. If the cooling system is installed separate from the heating system, generally an additional transformer is used. Specifically, in a system for heating only, a fan relay is generally not provided since the fan is generally controlled directly by a thermal switch on the furnace. Therefore, it is common in a system for heating only that the only electrical load on the transformer is the gas valve. When such a heating system is used in combination with a cooling system, the electrical load increases due to the addition of the fan relay and the contactor. The existing transformer often does not have the required volt-ampere output to operate all the low-voltage operated devices, therefore, additional transformer load capacity for the cooling system is required. Often, a second independent transformer is utilized due to the increased electrical load requirements of the cooling system. Even if the first transformer has enough load capacity for heating and cooling systems, the second transformer is generally used so as to simplify the electrical wiring involved in the installation of the cooling system. It is desirable that a low-voltage space thermostat for controlling a single-stage heating and cooling system be constructed so as to enable it to be readily usable with either the single-transformer or two-transformer power source. While use with the single-transformer power source poses no problem, a problem exists when used with the two-transformer power source. The problem is that the two transformers might be interconnected at the thermostat in such a manner so that they are out of phase with each other, whereby the voltages at the secondary windings are additive and thereby an unacceptably high value of voltage potential may exist between various nodes in the two systems. For typical transformers having a rated 24 volt RMS secondary voltage, this unacceptably high value is approximately 68 volts peak voltage. One prior art approach to negating this problem has been to incorporate means for isolating the secondary windings of the two transformers from each other. For example, in a related art construction, typified in U.S. Patent 4,049,973 to Lambert, five wiring terminals are provided in the thermostat. Two of the thermostat terminals, isolated from each other with respect to the internal circuitry of the thermostat by a multi-position system selector switch, are normally connected together at the terminals by a removable wire jumper. When the heating and cooling system uses a single transformer, the wire jumper is retained, and one end of the secondary winding of the single transformer is connected to one of the two jumper-connected terminals. The other end of the secondary winding is connected through the fan relay, gas valve, and contactor to the remaining three terminals. When the heating and cooling system uses two transformers, the wire jumper is removed, and one end of the secondary winding of the first transformer is connected to one of the two terminals previously connected by the wire jumper. Further, one end of the secondary winding of the second transformer is connected to the other of the two terminals previously connected by the wire jumper. The other end of the secondary winding of the first transformer is connected through the gas valve to one of the three remaining terminals, and the other end of the secondary winding of the second transformer is connected through the fan relay and contactor to the remaining two terminals. Since the two terminals previously connected by the wire jumper are isolated from each other, the secondary windings of the two transformers are therefore also isolated from each other. A second approach for solving the aforementioned problem is described in U.S. Patent 4,898,229 to Brown et al. Brown et al. uses an integral circuit means to detect the existence of an unacceptably high voltage potential between the two wiring terminals. If an unacceptably high voltage potential is detected, the circuit means alerts the party installing the second transformer that the two transformers are out of phase. However, utilizing this method requires the installer to reverse the connection at the terminals. If the installer ignores the alert, the high-voltage potential is still present. Further, Brown et al. interconnects the heating and cooling transformers at terminal R of Figure 1. This interconnection is undesirable, as the National Electrical Code discourages such a connection. Applicant's invention is an alternative to Brown et al. and Lambert, in which the polarity of the transformers is not of concern, due to the use of full-wave rectifiers in the first embodiment and the isolation of the cooling system from the heating system by means of an isolation transformer for the second embodiment. US-A-4948044 discloses a power supply circuit for use with programmable electronic digital thermostats of the type including a controlled semiconductor switch connected in series with an external AC voltage source. This power supply circuit includes a first rectifier bridge coupled across the controlled semiconductor switch for rectifying the external AC voltage to produce a first DC voltage. The primary winding of a transformer is connected in series with the controlled semiconductor switch and the external AC voltage. A second rectifier bridge is connected across the secondary winding of the transformer for rectifying the AC current to produce a second DC voltage. A voltage regulator has an input coupled to the first and second rectifier bridges and an output for providing a predetermined supply voltage for the programmable electronic digital thermostat. The present invention provides a power supply for a thermostat for controlling a heating system and a cooling system, said power supply receiving power from the heating system and the cooling system, the heating system and the cooling system being powered by separate A.C. power sources, said power supply being characterised by: a first diode bridge electrically connected to the heating system, said first diode bridge having two input nodes and first and second output nodes wherein said heating system is electrically connected to said input nodes of said first diode bridge; a second diode bridge electrically connected to the cooling system, said second diode bridge having two input nodes and first and second output nodes, wherein said cooling system is electrically connected to said input nodes of said second diode bridge; means for providing power to said thermostat, having a current limiter and a power supply means, said first output node of said first diode bridge being electrically connected to said first output node of said second diode bridge, said second output node of said first diode bridge being electrically connected to said second output node of said second diode bridge, said first output node of said first diode bridge being electrically connected to said current limiter, said second output node of said first diode bridge being electrically connected to said power supply means, said current limiter being electrically connected to said power supply means, wherein said power supply means converts rectified power from said first diode bridge and said second diode bridge to D.C. power to power the thermostat, wherein said first diode bridge and said second diode bridge electrically isolate said heating system and said cooling system; an isolation transformer electrically connected between said input nodes of one said diode bridge and one said system; and first and second switch means, said first switch means being electrically connected across said input nodes of said first diode bridge, said second switch means being electrically connected across said input nodes of said second diode bridge, wherein said first and second switch means activate said heating and cooling systems respectively. BRIEF DESCRIPTION OF THE DRAWING Figure 1 illustrates a first embodiment of a wiring scheme in which the heating and cooling system may be connected to the thermostat. Figure 2 is a second embodiment of the invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Figure 1 is utilized to illustrate a means to eliminate the high voltage potential. Figure 1 is a heating and cooling system in which heating system 40 and cooling system 70 are provided with power from transformers 43 and 73, respectively. Heating system 40 is connected to thermostat 10 through terminals 51 and 52, whereas cooling system 70 is connected to a thermostat 10 through terminals 53 and 54. If cooling system 70 did not provide its own transformer 73, the cooling system could operate by sharing transformer 43 and connecting the terminals at nodes A and B. To operate thermostat 10 in this manner, terminals 54 and 51 would then be jumpered together. However, for this example both the heating system 40 and the cooling system 70 will have their own transformers 43 and 73, respectively. Thermostat 10 operates by turning heating system 40 or cooling system 70 on through a series of switches 11, 12, 13 and 14, and main relay 15. When switches 11, 12 and relay 15 are closed, the heating system operates. When switches 11 and 12 are open or relay 15 is open, heating system 40 does not operate. This system also works in the same manner for cooling system 70, wherein when switches 13 and 14, along with relay 15, are all closed, cooling system 70 operates. However, when switches 13 and 14 are open or relay 15 is open, cooling system 70 will not operate. Thermostat 10 receives power from power supply 19. Power supply 19 receives power from rectifiers 20 and 25 through current limiter 17. When either heating system 40 or cooling system 70 are not operating (switches 11 and 12 are open, or 13 and 14 are open) power is supplied through the rectifiers 20 and 25. Rectifiers 20 and 25 are connected to heating system 40 and cooling system 70 in parallel with switches 11, 12 and relay 15, and switches 13, 14 and relay 15, respectively. Therefore, if the cooling system was operating and the heating system was not operating, switches 11 and 12 would be open, putting full-wave rectifier 20 in series with transformer 43 and heating load 45 of heating system 40, therein power could be transmitted through full-wave rectifier 20. For this embodiment, full-wave rectifier 20 comprises a diode bridge comprising diodes 21, 22, 23 and 24. Power is then transmitted from full-wave rectifier 20 through current limiter 17 to power supply 19. Current limiter 17 prevents the current being transmitted through full-wave rectifier 20 from reaching a level in which heating system 40 would, in effect, turn on. Thus, current limiter 17 only allows leakage current through heating load 45. Should heating system 40 be operating, wherein switches 11 and 12, plus relay 15, are all closed and cooling system 70 is not operating, switches 13 and 14 being open, the thermostat would receive power in a similar manner as previously described; however, the power would be provided from cooling system 70 and full-wave rectifier 25 would be in series with transformer 73 and cooling load 75. Full-wave rectifier 25 comprises a diode bridge made up of diodes 26, 27, 28 and 29. If, however, neither heating system 40 nor cooling system 70 are operating, in other words, switches 11, 12, 13 and 14 are open, or relay 15 is open, thermostat 10 will receive power from both heating system 40 and cooling system 70. In this case, if transformers 43 and 73 are running at 24 volts RMS, it is possible to achieve a 24 volt RMS differential. This voltage differential would be located between nodes A and B or, in other words; between the nodes where cooling load 75 and transformer 73 are connected and the node where heating load 45 and transformer 43 are connected. This is possible if transformers 43 and 73 are connected out of phase. For example, if the transformer 43 was in a position where terminal 51 were to be positive, current would flow through diode 21 to power supply 19, through power supply 19 to common node 18, back through common node 18 to diode 28, through diode 28 to terminal 54 to transformer 73, thus permitting an electrical connection. This only happens when terminal 54 at that time is negative, it is then possible to create only a 24 volt RMS differential between nodes A and B. While this is an acceptable voltage differential, an interconnection between the transformers is not desired. If, however, terminals 51 and 54 were connected together as shown in Brown et al., a 68 volt peak voltage would be present between nodes A and B. Applicant's second embodiment provides a means in which it is impossible for an electrical connection to be had between transformers 43 and 73. Figure 2 demonstrates the second embodiment of this invention. As shown, the electrical circuit of Figure 2 is quite similar to Figure 1. The main difference between Figure 1 and Figure 2 is the addition of an isolating transformer 30 to full-wave rectifier 25. By removing the direct connections to terminals 53 and 54 to full-wave rectifier 25 and inserting between them isolating transformer 30, the possibility of interconnecting transformers 43 and 73 is eliminated. Isolation transformer 30 is connected in parallel with switches 13, 14 and relay 15. In this manner, when switches 13, 14 and relay 15 are all closed, isolation transformer 30 is, in essence, shorted out. However, when switches 13 and 14, or relay 15, are open, isolation transformer 30 is in series with transformer 73 and cooling load 75. Isolation transformer 30 is a one-to-one transformer. However, in a system where neither heating system 40 or cooling system 70 are operating, as previously discussed in the background, it is possible to have a voltage differential of 68 volts peak voltage. By the introduction of isolation transformer 30 and use of full-wave rectifier 25, which is a diode bridge, there will be no interconnection of cooling transformer 73 with heating transformer 43. As it is no longer possible for an installer to connect cooling transformer 73 out of phase with heating transformer 43, this system becomes simpler to correctly install and safer to use. Figure 2, which is the preferred embodiment, demonstrates a system in which only two primary system transformers are utilized. However, if one were to desire adding additional systems, it would be possible to add these additional systems provided these systems are added utilizing the full-wave rectifier and isolation transformer system to connect the new system to the secondary power supply or thermostat 10 of Figure 2. Therefore, it is possible to utilize a plurality of systems and eliminate the possibility of interconnecting any of the transformers so that the phasing of the transformers is immaterial.

Claims: A power supply for a thermostat (10) for controlling a heating system (40) and a cooling system (70), said power supply receiving power from the heating system and the cooling system, the heating system and the cooling system being powered by separate A.C. power sources, said power supply being characterised by: a first diode bridge (20) electrically connected to the heating system (40), said first diode bridge having two input nodes (22 and 24) and first (21) and second (23) output nodes wherein said heating system (40) is electrically connected to said input nodes (22,24) of said first diode bridge (20); a second diode bridge (25) electrically connected to the cooling system (70), said second diode bridge (25) having two input nodes (27 and 29) and first (26) and second (28) output nodes, wherein said cooling system (70) is electrically connected to said input nodes (27,29) of said second diode bridge (25); means for providing power to said thermostat (10), having a current limiter (17) and a power supply means (19), said first output node (21) of said first diode bridge (20) being electrically connected to said first output node (26) of said second diode bridge (25), said second output node (23) of said first diode bridge (20) being electrically connected to said second output node (28) of said second diode bridge (25), said first output node (21) of said first diode bridge (20) being electrically connected to said current limiter (17), said second output node (23) of said first diode bridge (20) being electrically connected to said power supply means, said current limiter (17) being electrically connected to said power supply means (19), wherein said power supply means (19) converts rectified power from said first diode bridge (20) and said second diode bridge (25) to D.C. power to power the thermostat (10), wherein said first diode bridge (20) and said second diode bridge (25) electrically isolate said heating system (40) and said cooling system (70); an isolation transformer (30) being electrically connected between said input nodes of one of said diode bridges (20,25) and one of said heating (40) and cooling (70) systems, and first and second switch means, said first switch means (11, 12, 15) being electrically connected across said input nodes (22,24) of said first diode bridge (20), said second switch means (13, 14, 15) being electrically connected across said input nodes (27,29) of said second diode bridge (25), wherein said first (11,12,15) and second (13,14,15) switch means activate said heating (40) and cooling (70) systems respectively. A power supply according to Claim 1, characterised in that the isolation transformer (30) is electrically connected between said input nodes (22,24) of said first diode bridge (20) and said heating system (40). A power supply according to Claim 1, characterised in that the isolation transformer (30) is electrically connected between said input nodes (27,29) of said second diode bridge (25) and said cooling system (70).

Inventors: RATZ JAMES W, RATZ, JAMES W.
Applicants: HONEYWELL INC, HONEYWELL INC.
Application year: 1992
Main classification: G05D23
IPC codes: G05F1