Patent Description:
In-floor heating systems, such as radiant floor heating systems, continue to grow in popularity both in new construction and remodeling of homes and commercial buildings. Installation of such in-floor heating systems generally necessitates a relatively high level of skill and training for installers, as well as multiple specialized tools and processes to ensure proper installation.

For example, installers of in-floor heating systems generally go through training in a wide range of related topics including, for example, thin-set and thick-set mortaring practices (and associated set times), electrical requirements and basic electrical safety, and manufacturer-specific guidelines and precautions. Unfortunately, many installers receive inadequate training. However, even the most trained and observant installers can make mistakes during installation, with those mistakes leading to premature component failures, increased service costs, and potentially dangerous conditions for both the installer and the end-user. In this context, document <CIT> refers to an electrical heating system for use in uniform heating surfaces. A heating element is constructed of mesh screen comprised of small gauge wires, which are spaced in a close mesh arrangement such that the total surface area of the wires is substantially equal to or greater than the adjacent area of the surface to be heated. The longitudinal wires are electrically conductive and are preferably made of a nonferrous metal and the transverse wires are coated with an insulating material, thermally conductive and interwoven with the longitudinal wires. The heating element is positioned substantially parallel to and adjacent the surface to be heated. The heating system includes electronic circuitry which essentially eliminates transmission of power surges, voltage spikes and chatter when the heating system is connected to an alternating current power source. The heating system also includes protective circuits and devices for preventing injury or damage due to transformer overheating, or due to under-current or over-current conditions. An optimal electronic circuit permits use of the device for preventing formation of ice on surfaces in an efficient and economical manner. Furthermore, document <CIT> refers to detecting accurately an insulation fault in a load circuit, Power supply lines and an electric heater (a load circuit) are connected by a detecting portion to detect a detected voltage (detected value) in accordance with the magnitude of a leakage current Id that flows through a ground between the power supply lines and the electric heater, and an evaluation as to whether or not there is a breakdown of insulation of the electric heater relative to the ground is performed by an evaluating portion based on the detected value obtained when the relay contact points are open. According to <CIT>, a thermostat that is configured to be releasably secured to a wall mountable connector, wherein the wall mountable connector includes a jumper switch that permits an installer or other professional to easily form an electrical connection between different wiring terminals of the wall mountable connector in accordance with how particular field wires are connected to the wiring terminals of the wall mountable connector. The thermostat is further configured to automatically determine the position of the jumper switch of the wall mountable connector, and in some cases, change the control of at least some functionality of the thermostat and/or HVAC equipment depending on the position of the jumper switch. Furthermore, document <CIT> refers to a thermostat equipped with a residual current device, comprising a relay, a connector, a capacitor, a circuit breaker, and a measurement coil. The thermostat comprises at least two printed circuit boards (PCB), a first PCB and a second PCB. The relay, the connector and the circuit breaker are connected to the first PCB and the measurement coil is connected to the second PCB.

Various aspects, features and advantages of the present disclosure will be better understood by reading the following detailed description, taken together with the drawings wherein:.

The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the teaching of the present specification and are not intended to limit the scope of what is taught in any way.

As discussed above, installation of in-floor heating systems raise numerous non-trivial challenges, even for experienced installers who receive adequate training. Such challenges include accidentally damaging a heating element (also referred to herein as a heating mat, or simply a mat) during installation, and not discovering the damage until after the mortar has set. In addition, careful attention must be paid to max current and voltage ratings for heating mats and associated cabling. Over-current situations and/or operating a 120Vac heating mat with a 220Vac source can cause system failure, or worse yet, create unsafe conditions for the installer and/or the end-user.

In recognition of these challenges, installers often utilize a number of tools including multi-meters, clamping current meters, continuity testers, line-fault testers, wire strippers, and other standard tools such as hammers and trowels. Installers generally perform a number of safety checks and confirmations at various stages of installation such as measuring electrical resistances of the heating mat and associated cables, double checking current and voltage ratings of a mat in view of the provided AC source/circuit, performing current measurement and voltage measurements for verification, and so on. Continued improvements in the context of in-floor heating systems depend at least in part on simplifying installation procedures to reduce the potential for installation errors, undiscovered/latent damage to in-floor heating systems during installation, and creation of unsafe conditions.

Thus, in accordance with an embodiment, a thermostat adapter is disclosed for use during installation and testing of in-floor heating systems. The thermostat adapter may also be referred to herein as an adapter device or simply an adapter. The adapter device allows for temporary electrical interconnection between a mat and an AC power source, and includes one or more switches configured to actuate, e.g., based on a user-supplied force, and temporarily electrically couple a heating mat to an AC power source to energize the same. Preferably, the one or more switches are implemented as momentary switches to automatically de-actuate, e.g., transition from a closed to an open state/orientation, in response to the absence of the user-supplied force.

In addition, the adapter device is configured to removably couple to a thermostat device and provide electrical power to the same based on, for example, actuation of the one or more momentary switches. A user may then subsequently select one or more options via a display of the thermostat device to momentarily energize the mat via the AC power source, and/or perform one or more test and diagnostic processes as variously disclosed herein. Preferably, the adapter device is configured with a second switch that operates as an interrupt that prevents energizing pins/terminals of the adapter device and/or the mat with AC power in the event the thermostat device is decoupled from the adapter device. In any such cases, the adapter device allows for a user to immediately interrupt AC power to the thermostat device and/or the mat by simply removing pressure (or otherwise de-actuating) at least one of the momentary switches.

Various aspects and features disclosed herein are also directed to a thermostat device, also referred to herein as a control unit, having at least one power measurement circuit to measure an electrical characteristic of an AC power source and/or mat. In an embodiment, the thermostat device further includes hardware and/or software (e.g., firmware) to adjust operation of an in-floor heating system, e.g., a temperature set point, schedule to establish automatic floor heating on/off times and temperatures, and so on. The thermostat device may also be referred to as a so-called "smart" thermostat based on the ability of the thermostat to utilize the at least one power measurement circuit to, for example, verify voltage compatibility between a mat and an AC source, monitor for overcurrent conditions, and/or perform long-term measurement sampling to allow power measurement tracking and reporting (e.g., Kilowatt usage per hour, day, month).

Moreover, the smart thermostat can also provide cost estimates for a user, e.g., based on interpolation from previous/historical power measurements from the at least one power measurement circuit, heuristics, and/or a combination of both, to allow the user to set schedules and operate an in-floor heating system in an informed manner.

In one non-limiting preferred embodiment, a thermostat device consistent with the present disclosure can include features and functions of existing thermostat controllers, the aforementioned "smart" features discussed above, and/or installation functions and features such as momentary tests, electrical characteristic measurements for an AC source and heating mat, and line-fault tests to alert installers to faults prior to mortar curing.

Further, a thermostat device consistent with the present disclosure allows for simple registration with a remote server, e.g., via the Internet, and storing of various electrical and configuration parameters for operation of the in-floor heating system, and measurements taken during test modes and/or power sampling for cost estimates and reporting purposes. Such registration can occur via user input at the thermostat (e.g., via a touch screen display provided by the thermostat) and/or through an "App" executed on a mobile computing device such as a smart phone, tablet, or laptop. Preferably, the app of the mobile computing device can utilize a fiducial such as a QR code disposed on the thermostat to determine a unique identifier (ID) for the thermostat along with other related parameters.

For example, the app of the remote computing device may utilize the unique ID to register with a remote computer server, e.g., hosted by a manufacturer, and/or to initiate communication with the thermostat, e.g., via wireless protocols such as Wi-Fi, Bluetooth, near-field communication, and so on. The various mat-related electrical parameters (also referred to herein as predefined electrical values) may be provided manually by a user, and/or preferably through the app of the mobile computing device that can scan a fiducial such as a QR code disposed on the heating mat (and/or printed documentation). The predefined electrical values may therefore comprise, for example, a maximum voltage rating for the heating element (e.g., 120Vac or <NUM>/240Vac) and the maximum current rating for the heating element (e.g., 5A, 10A). The thermostat may then utilize the predefined electrical values during testing and diagnostics procedures to detect fault conditions as variously disclosed herein. It should be appreciated that a predefined voltage parameter (e.g., predefined voltage rating, predefined current rating, predefined maximum current rating, or the like) may be a single value or a range of values.

Accordingly, the present disclosure provides numerous advantages and features over existing approaches to in-floor heating system installation and testing. For example, various aspects and features disclosed herein include providing a modular arrangement of components that integrate and couple together to provide a single point of electrical interconnection, e.g., between terminals of a heating mat and conductors providing AC power, and a safety interlock that prevents energizing of a heating mat (and/or the thermostat) in the event of an electrical misconfiguration or fault condition.

Thus, an adapter and thermostat consistent with the present disclosure provides a portable and safe approach to providing temporary electrical interconnection between AC power sources and a heating mat, and the ability to perform robust diagnostics and tests through, for instance, the push of one or more buttons (e.g., the push of a single button). The results of tests and diagnostics may then be seamlessly provided to remote hosts/servers, e.g., via the Internet, for purposes of technical support, quality control, and proper installation verification.

The term substantially, as generally referred to herein, refers to a degree of precision within acceptable tolerance that accounts for and reflects minor real-world variation due to material composition, material defects, and/or limitations in manufacturing processes. Such variation may therefore be said to achieve largely, but not necessarily wholly, the target/nominal characteristic. To provide one non-limiting numerical example to quantify "substantially," such a modifier is intended to include minor variation that can cause a deviation of up to and including ± <NUM>% from a particular stated quality/characteristic unless otherwise provided by the present disclosure.

The term "coupled" as used herein refers to any connection, coupling, link or the like between elements/components. In contrast, directly coupled refers to two elements in contact with each other in a manner that does not include an intermediate element/component disposed therebetween.

The use of the terms "first," "second," and "third" when referring to elements herein are for purposes of clarity and distinguishing between elements, and not for purposes of limitation. For example, the first switch <NUM>-<NUM> of <FIG> discussed below may also be referred to as a second switch, and likewise, the second switch <NUM>-<NUM> of <FIG> may also be referred to as a first switch in some scenarios. Likewise, like numerals are utilized to reference like elements/components between figures.

Turning to the Figures, <FIG> illustrates an example system <NUM> for use during installation, testing, and diagnostics of in-floor heating elements/systems. As shown, the system <NUM> includes an adapter device <NUM>, an optional base <NUM>, a thermostat <NUM>, an optional mobile computing device <NUM>, and a heating element <NUM> (also referred to herein as an in-floor heating element, a heating element, or simply a mat).

Note, the adapter device <NUM> may also be referred to herein as a thermostat adapter, or simply an adapter. In accordance with an embodiment, the adapter device <NUM> is configured for coupling to a thermostat (e.g., thermostat <NUM>) and providing temporary electrical interconnection between the thermostat, an in-floor heating element (e.g., heating element <NUM>), and an AC power source during installation and testing of the in-floor heating element.

The adapter device <NUM> includes a housing <NUM> having a plurality of sidewalls that define a cavity, e.g., cavity <NUM> of <FIG>. The adapter device <NUM> includes at least first and second terminal blocks <NUM>-<NUM>, <NUM>-<NUM> coupled to the housing <NUM>. Each of the first and second terminal blocks <NUM>-<NUM>, <NUM>-<NUM> can be disposed on the same or different sidewalls of the housing <NUM>. Preferably, the first and second terminal blocks <NUM>-<NUM>, <NUM>-<NUM> are disposed on opposite and/or separate sidewalls of the housing <NUM>. Note, the adapter device <NUM> can also utilize other types of electrical couplers/sockets as an alternative to, or in combination with, the first and second terminal blocks <NUM>-<NUM>, <NUM>-<NUM>, and this disclosure is not intended to be limiting in this regard. For example, and as discussed below, the first terminal block <NUM>-<NUM> can be alternatively implemented as C14 male plug, for example, and not necessarily a terminal block that is configured to receive and electrically couple to bare conductor wire.

Continuing on, the first terminal <NUM>-<NUM> can be implemented as, for instance, an N-pole terminal plug to removably couple to conductors provided by, for instance, <NUM> or <NUM> AWG wire. The first terminal block <NUM>-<NUM> may also be referred to as an AC power source interconnect. Preferably, the first terminal block <NUM>-<NUM> is implemented as a <NUM> pin Electrical AC Power Socket that can couple to an IEC-<NUM>-C13 or IEC-<NUM>-C14 plug. In any such cases, the first terminal block <NUM>-<NUM> can couple to conductors (e.g., L1, L2) to receive a power signal <NUM> in the form of an alternating current (AC) from AC mains, for instance.

The second terminal block <NUM>-<NUM> can also be implemented as, for instance, an N-pole terminal plug to removably couple to associated terminals of heating element <NUM> via <NUM> or <NUM> AWG wire, for example. The second terminal block <NUM>-<NUM> may also be referred to as a heating element interconnect. Preferably, the second terminal block <NUM>-<NUM> includes a plurality of conductor slots/openings, with each conductor opening configured to receive a bare end of a conductor wire and a clamping arrangement, e.g., a screw-actuated clamp, configured to securely couple the received conductor wire into an associated conductor opening. In an embodiment, such as shown below and discussed with reference to <FIG>, the second terminal block <NUM>-<NUM> preferably includes a cover <NUM> to provide wire strain relief and to reduce the potential of user contact with energized conductor wires.

However, other electrical interconnection approaches are within the scope disclosure including alligator clips, wire nuts, or any other suitable approach that allows for temporary electrical interconnection between heating element <NUM> and the second terminal block <NUM>-<NUM>. Note, heating element <NUM> can comprise N number of heating elements electrically coupled to each other, e.g., in parallel, and the embodiment of <FIG> is not intended to be limiting. Further, the N number of heating elements may be disposed within flooring of this and covered by, for instance, tile. Thus, the heating element <NUM> may also accurately be referred to herein as an in-floor heating element.

The adapter device <NUM> further includes a safety interlock <NUM>. The safety interlock <NUM> is configured to interrupt/disconnect electrical communication between an AC power source providing the power signal <NUM> and the heating element <NUM>. In an embodiment, the safety interlock <NUM> comprises at least one momentary switch that includes a normally-open configuration. For example, as shown in <FIG>, the safety interlock <NUM> comprises first and second switches <NUM>-<NUM>, <NUM>-<NUM>. As discussed in further detail below with reference to <FIG>, the first switch <NUM>-<NUM> can be disposed on the housing <NUM> of the adapter device <NUM> (e.g., see switch <NUM>-<NUM> in <FIG>) to allow a user to selectively actuate the same, e.g., via a finger press. The first switch <NUM>-<NUM> can therefore be configured to transition from an open state to a closed state based on user input. Preferably, the first switch <NUM>-<NUM> comprises a momentary switch having a spring member (not shown) to automatically transition the first switch <NUM>-<NUM> from a closed state to an open state in response to the absence of a user-supplied force.

The second switch <NUM>-<NUM> can be disposed in a location on the housing <NUM> at which the thermostat <NUM> removably couples to the adapter device <NUM> (e.g., see switch <NUM>-<NUM> in <FIG>). The second momentary switch can also be configured to transition from the open state to the closed state based on, for instance, the thermostat <NUM> being coupled to the adapter device <NUM>.

Various examples and scenarios disclosed herein refer to the safety interlock <NUM> being configured to block/lock based on the state of the first and/or second switches <NUM>-<NUM>, <NUM>-<NUM>. However, the safety interlock <NUM> may also utilize additional switches such as one or more pins of the plurality of pins <NUM> (See <FIG>) configured as interrupt switches (also referred to herein as micro interrupt switches). Thus, the safety interlock <NUM> can utilize N number of switches and be configured to, in a general sense, logically AND the state of each switch of the adapter device <NUM> to prevent unsafe conditions, i.e., supply electrical power to the thermostat <NUM> and/or heating element <NUM> in the event one or more of the switches are in an open state.

In the specific non-limiting example of <FIG>, the safety interlock <NUM> is configured to prevent (or interrupt) electrical communication between the heating element <NUM> and the AC power source providing the power signal <NUM> in the event that the first and/or second switches <NUM>-<NUM>, <NUM>-<NUM>, transitions to an open state. Alternatively, or in addition, the blocked state may also include the safety interlock <NUM> being configured to prevent or otherwise interrupt electrical communication between the thermostat <NUM> and the AC power source providing the power signal <NUM>.

As further shown, the adapter device <NUM> can couple to thermostat, e.g., thermostat <NUM>, via an optional thermostat base <NUM> (also referred to herein as a base) and/or directly couple to a thermostat without an intermediate base. The thermostat base <NUM> may be configured to allow for wall/surface mounting (post installation), and in some cases, to provide backplane circuitry to allow a thermostat coupled thereto to electrically connect with, for instance, AC mains, one or more floor sensors, and the heating elements <NUM>. However, such backplane circuitry can be integrated into thermostats (e.g., into a single housing of a thermostat), and this disclosure is not limited in this regard.

As discussed in greater detail below with regard to <FIG>, the adapter device <NUM> can include a thermostat coupling section that allows for the thermostat <NUM> and/or thermostat base <NUM> to removably couple to, and electrically communicate with, an AC power providing the power signal <NUM> and/or the heating element <NUM>.

Preferably, the adapter device <NUM> includes a thermostat coupling section <NUM> that enables coupling to a wide-range of thermostat types and/or associated bases to provide, in a general sense, a universal thermostat adapter. To this end, the thermostat coupling section <NUM>, which may also be referred to herein as a thermostat coupling region, can include one or more temporary electrical interconnects to electrically couple to the thermostat <NUM>. For example, and as shown <FIG>, the thermostat coupling section <NUM> includes a plurality of pins <NUM> that allow for coupling to virtually any thermostat and/or thermostat base that has electrically conductive contacts/pads disposed at positions that align with the pins <NUM>.

Continuing on, and as shown in <FIG>, a switching arrangement <NUM> is at least partially implemented within the thermostat base <NUM> and/or thermostat <NUM>. Alternatively, or in addition, the switching arrangement <NUM> may be implemented within the adapter device <NUM>, and/or, collectively implemented by circuitry/components of the thermostat <NUM>, thermostat base <NUM>, and/or adapter device <NUM>. The switching arrangement <NUM> may also be referred to herein as a heating element control circuit. Preferably, the switching arrangement <NUM> is implemented at least partially within a housing <NUM> of the thermostat <NUM> to provide a range of testing functions and features disclosed herein without necessarily utilizing the thermostat base <NUM> or the adapter device <NUM>.

In any such cases, the switching arrangement <NUM> includes at least one switch, e.g., switch <NUM>. The switch <NUM> switchably electrically couples a first conductor (L1) of the first and second terminals <NUM>-<NUM>, <NUM>-<NUM> together. In an embodiment, the switch <NUM> includes one or more mechanical relays, or one or more high-current metal-oxide-semiconductor field-effect transistor (MOSFETs), commonly referred to as power MOSFETs, or a combination of such mechanical and solid-state components depending on a desired configuration.

In the embodiment of <FIG>, the switch <NUM> includes first and second switch terminals <NUM>-<NUM>, <NUM>-<NUM> to complete a circuit that electrically couples the heating element <NUM> to an AC power source providing the power signal <NUM> in order to energize the heating element <NUM> and cause the same to radiate/emit heat <NUM>. To this end, the switch <NUM> can be configured to transition between an open and closed state/orientation to switchably electrically decouple and couple, respectively, the heating element <NUM> to the power signal <NUM> of the AC power source.

Notably, the switch <NUM> is prevented/blocked from completing a circuit between the heating element <NUM> and AC power source providing the power signal <NUM> when the safety interlock <NUM> is in a locked/block state, e.g., based on the first and/or second switch <NUM>-<NUM>, <NUM>-<NUM>, being in an open state as discussed above. On the other hand, the switch <NUM> is able to complete the circuit between the heating element <NUM> and the AC power source providing the power signal <NUM> when the safety interlock <NUM> is in an unlocked/safe state, e.g., based on the first and/or second switch <NUM>-<NUM>, <NUM>-<NUM>, being in a closed state.

As shown, the thermostat <NUM> can include a plurality of components to support installation, diagnostics, and testing of in-floor heating elements. The thermostat <NUM> may include the housing <NUM>, the controller <NUM>, an optional display <NUM>, an optional network interface circuit (NIC) <NUM>, optionally memory <NUM>, an optional speaker <NUM>, an optional antenna device <NUM>, and optional power measurement circuitry <NUM>.

The controller <NUM> comprises at least one processing device/circuit such as, for example, a microcontroller (MCU), a digital signal processor (DSP), a field-programmable gate array (FPGA), Reduced Instruction Set Computer (RISC) processor, x86 instruction set processor, microcontroller, an application-specific integrated circuit (ASIC).

The controller <NUM> may comprise a single chip, or multiple separate chips/circuitry. The controller <NUM> can implement various methods and features disclosed herein, e.g., process <NUM> of <FIG>, using software (e.g., C or C++ executing on the controller <NUM>), hardware (e.g., circuitry including hardcoded gate level logic or purpose-built silicon) or firmware (e.g., embedded routines executed by the controller <NUM>), or any combination thereof. The controller <NUM> can communicatively couple with components of the thermostat <NUM> such as the NIC <NUM>, the display <NUM>, the memory <NUM>, via a data bus, for example, to execute various processes and features disclosed herein.

The display <NUM> can comprise any suitable device such as a liquid crystal display (LCD) to allow for visualization of operational status, configuration menus, and other visual elements that allow for rendering of information to a user/installer. Preferably, the display <NUM> implements touch-screen functionality to allow for a user to navigate between menus, initiate one or more test modes as disclosed herein, and adjust settings such as a current temperature for the heating element <NUM> via touch gestures and actions such as swipes, flicks, and taps. The display <NUM> may therefore also be referred to as a touch-sensitive display.

The NIC <NUM> can comprise one or more circuits/chips that allow for the sending and receiving of radio frequency (RF) signals, and preferably for sending and receiving RF signals <NUM> that comport with WiFi standards such as <NUM>. However, the NIC <NUM> can be configured to implement one or more of a wide-range of wireless standards including, for instance, Bluetooth, Bluetooth Low Energy (BLE), Near-Field Communication (NFC), ZigBee, and so on. Preferably, the NIC <NUM> supports one or more wireless protocols for communicating with remote sensors such as remote temperature sensors.

Thus, the thermostat <NUM>, and more specifically processes executed via controller <NUM> can send and receive data with a remote host, such as mobile computing device <NUM> and/or a computer server operated by a manufacturer of the thermostat <NUM> using a wide area network (WAN) as such as the Internet. The thermostat <NUM> can be configured to communicate directly with the mobile computing device <NUM>, e.g., via Bluetooth, NFC, or indirectly via a wireless access point, e.g., via WiFi.

Moreover, the thermostat <NUM> may also be configured to utilize the mobile computing device <NUM> as an access point/proxy to allow the thermostat <NUM> to communicate with remote hosts through, for instance, a cellular data connection provided by the mobile computing device <NUM>. Thus, the thermostat <NUM> may directly couple with the mobile computing device <NUM> by way of NIC <NUM> forming a Bluetooth/BLE connection with the same, and then communicate with one or more remote hosts via a cellular Internet gateway provided by the mobile computing device <NUM>.

The memory <NUM> can comprise one or more volatile and/or non-volatile memory chips. The memory <NUM> can include machine-readable instructions, e.g., compiled or interpretable code, to allow for controller <NUM> to execute various processes such as thermostat control routines, user interface routines, and testing and diagnostic modes and processes as variously disclosed herein (e.g., see process <NUM> of <FIG>). In an embodiment, various mat-related electrical parameters (also referred to herein as predefined electrical values) may be stored in the memory <NUM>. The predefined electrical values can comprise, for example, a maximum voltage rating for the heating element <NUM> (e.g., 120Vac or <NUM>/240Vac) and the maximum current rating for the heating element <NUM> (e.g., 15A, 20A). In addition, the memory <NUM> can include a representation of a schedule that automatically energizes/de-energizes heating element <NUM> on specific days and times.

The optional speaker <NUM> can comprise any speaker device capable of being driven by controller <NUM> to output generated or predefined sounds. The optional speaker <NUM> may also be implemented as a piezoelectric buzzer. The optional speaker <NUM> may be disposed within the housing <NUM> of the thermostat <NUM>, or other suitable location such as within the housing <NUM> of the adapter device <NUM>. Predefined sounds may be stored as digitized samples in the memory <NUM>, and the controller <NUM> may therefore retrieve the digitized samples and cause the optional speaker <NUM> to output/emit the same in an analog fashion as sound energy. Alternatively, or in addition, the controller <NUM> may generate various synthetic tones/sounds (e.g., by generating digital samples at one or more target frequencies) for output by the optional speaker <NUM>.

In an embodiment, the thermostat <NUM> communicates with the mobile computing device <NUM> via RF signals <NUM>, as discussed above. In this embodiment, an "app" executed on the mobile computing device <NUM> visualizes a user interface <NUM>. The user interface <NUM> can include a plurality of user-selectable elements, e.g., e.g., buttons, that allow installation and diagnostic functions of the system <NUM> to be performed/initiated via the mobile computing device <NUM>. For example, the user interface <NUM> of the mobile computing device <NUM> can assist in initial configuration of the thermostat <NUM> by allowing for the same to be identified via protocols implemented by the NIC <NUM>, e.g., Bluetooth/BLE. Alternatively, or in addition, the mobile computing device <NUM> can include an image sensor to detect a fiducial disposed on the thermostat <NUM> for identification purposes and/or to initiate secure wireless communication between the mobile computing device <NUM> and the thermostat <NUM>. Once identified, the user interface <NUM> can initiate a provisioning sequence based on user input to provide, for example, Wi-Fi access point details and authentication parameters (also referred to herein as WiFi Settings) to the thermostat <NUM> for storage in memory <NUM>.

In addition, the user interface <NUM> of the "app" executed on the mobile computing device <NUM> may be configured to "mirror" or otherwise provide redundant access to features and functions of the thermostat <NUM> such that accessing the display <NUM> to view operational status, adjust settings, and perform various installation and diagnostic-related functions becomes optional. Accordingly, the thermostat <NUM> can operate headless (e.g., without a display <NUM>, or via a limited number of visual indicators such as LEDs), however, the thermostat <NUM> preferably includes the display <NUM> to provide flexibility and simplify use of the thermostat <NUM> by an installer/user.

It should be noted that various features and aspects of user interface <NUM> and the "app" visualizing the same via the mobile computing device <NUM> as disclosed herein may also be implemented by the thermostat <NUM>, e.g., in combination with controller <NUM>, display <NUM>, and memory <NUM>. For example, the look, feel, and functionality of the "app" and user interface <NUM> of the mobile computing device <NUM> may be substantially similar to a user interface shown via display <NUM> of the thermostat <NUM>. Accordingly, the features and functions of the "app" and user interface <NUM> discussed above are equally applicable to a user interface and user experience implemented by the thermostat <NUM> and will not be repeated for brevity.

As further shown in <FIG>, the thermostat <NUM> includes power measurement and monitoring circuitry <NUM> electrically coupled to conductors L1/L2. The power measurement and monitoring circuitry <NUM> may also be referred to herein as power measurement circuitry. Preferably, the power measurement and control circuitry <NUM> is at least partially disposed in the housing <NUM> of the thermostat <NUM>. In scenarios where the thermostat <NUM> is implemented as a thermostat, this advantageously allows the thermostat <NUM> to perform various diagnostic and test procedures as disclosed herein without necessarily requiring the adapter device <NUM>. However, the power measurement circuitry <NUM> may be implemented at least in part within the housing <NUM> of the adapter device <NUM>, and/or within the optional base <NUM>.

In any such cases, and as discussed in greater detail below with reference to the example circuits of <FIG>, the power measurement circuitry <NUM> can include one or more power measurement circuits configured to measure an electrical characteristic of the power signal <NUM> of the AC source and/or of the heating element <NUM>. In an embodiment, the power measurement circuitry <NUM> includes at least one power measurement circuit implemented as the ammeter circuit <NUM> of <FIG> to, for instance, detect an overcurrent condition of the heating element <NUM>, and/or the voltage monitoring circuit <NUM> of <FIG> to detect, for example, a voltage mismatch between the power signal <NUM> and the heating element <NUM> (e.g., <NUM>/240Vac power source coupled to a 120Vac rated mat).

Preferably, the power measurement circuitry <NUM> includes at least two power measurement circuits which are each configured to measure a different power characteristic of the power signal <NUM> and/or the heating element <NUM>. To this end, and returning to the prior example, an embodiment of the power measurement circuitry <NUM> can include a first power measurement circuit configured as the ammeter circuit <NUM> of <FIG>, and a second power measurement circuit configured as the voltage monitoring circuit <NUM> of <FIG>. In addition, this embodiment can also include the power measurement circuitry <NUM> having a third power measurement circuit configured as the line-fault monitoring circuit <NUM> of <FIG>. Each of the first, second, and/or third power measurement circuits can be implemented within the housing <NUM> of the thermostat <NUM> to advantageously provide a thermostat having a range of test and power monitoring features.

The power measurement circuitry <NUM> generally includes a high-power side, e.g., to couple to an AC power source and receive a 120Vac or 220Vac power signal <NUM>, and a low-power side with a power rail that provides <NUM> volts, or preferably <NUM>. 3V DC, to relatively low-power components/chips such as hall effect sensors. Electrical isolation may be provided through the use of a transformer or other suitable device capable of providing galvanic isolation between the aforementioned high and low-power sides. Such components can require a significant amount of space within the housing <NUM> of the thermostat <NUM>. Accordingly, the power measurement circuitry <NUM> may also be implemented at least in part within a separate housing that electrically couples to the thermostat <NUM>, and preferably in a separate housing/device that can communicate wirelessly with the thermostat <NUM> via NIC <NUM>, for example. In an embodiment, the power measurement circuitry <NUM> can also include an overload interrupt circuit (OIC) <NUM> that can detect overcurrent conditions, e.g., a current drawn by the heating element <NUM> in excess of a threshold target such as <NUM> Amperes (A), and can output a signal or otherwise communicate with controller <NUM> to indicate an overcurrent fault or normal state.

<FIG> shows another example system <NUM> consistent with aspects of the present disclosure. The system <NUM> may be configured substantially similar to that of the system <NUM> of <FIG>, and like reference numerals refer to like elements. However, as shown in <FIG>, the system <NUM> includes an adapter device <NUM>' that can operate with a standard thermostat <NUM>, and provide temporary electrical interconnection between an AC source <NUM> and the heating element <NUM> via, for instance, first and/or second switches <NUM>-<NUM>, <NUM>-<NUM>. The thermostat <NUM> may not necessarily include, for instance, components such as the power measurement circuitry <NUM>, NIC <NUM>, and so on as shown above in <FIG>. Instead, the adapter <NUM>' can implement various components of the thermostat <NUM> (<FIG>) such as the controller <NUM>, the display <NUM>, the NIC <NUM>, the memory <NUM>, and the power measurement circuitry <NUM>. Thus, the system <NUM> can provide an adapter device <NUM>' that supports a range of existing thermostats that do not necessarily include the "smart" functions and capabilities disclosed herein.

Turning to <FIG>, an example adapter device <NUM> suitable for use within the example system <NUM> is shown. As shown, the adapter device <NUM> includes a housing <NUM> defined by a plurality of sidewalls, e.g., sidewalls <NUM>-<NUM> to <NUM>-<NUM>. The housing <NUM> comprises plastic, metal, or any other suitably ridged material. Preferably, the housing <NUM> is formed of an electrically insulative material having a relatively high dielectric (Dk) constant of at least <NUM>, e.g., Acrylonitrile Butadiene Styrene (ABS) which has a Dk between <NUM> and <NUM>.

As further shown, the first sidewall <NUM>-<NUM> (See <FIG>) of the housing <NUM> provides a first switch <NUM>-<NUM> disposed thereon. The second sidewall <NUM>-<NUM> (See <FIG>) of the housing <NUM> defines a thermostat coupling section <NUM>. The third sidewall <NUM>-<NUM> (See <FIG>, <FIG>) of the housing <NUM> provides at least a first portion of the heating element coupling section <NUM>. The fourth sidewall <NUM>-<NUM> of the housing <NUM> provides a temporary mounting member <NUM>. The fifth sidewall <NUM>-<NUM> provides an AC coupling section <NUM> with a port/socket (not shown) to couple to, for instance, a male or female plug comporting with IEC-<NUM>-C13 or IEC-<NUM>-C14, for example. The sixth sidewall <NUM>-<NUM> (See <FIG>) provides at least a second portion of the heating element coupling section <NUM>.

Each component of the adapter device <NUM> will now be discussed in turn, and with reference to a particular sidewall providing the component for clarity and ease of description. However, the particular configuration shown in <FIG> is not intended to be limiting. For example, the housing <NUM> can include other shapes and profiles and not necessarily a rectangular profile as shown. Likewise, various components such as the first switch <NUM>-<NUM> and temporary mounting member <NUM> may be disposed at other locations on the housing <NUM> with minor modification, and each component is not intended to be limited to only the sidewalls/locations shown.

Continuing on, the housing <NUM> further includes the temporary mounting member <NUM> disposed adjacent an interface/transition between the fourth sidewall <NUM>-<NUM> and the sixth sidewall <NUM>-<NUM>. The temporary mounting member <NUM> is configured to allow the housing <NUM> of the adapter device <NUM> to be temporarily attached/mounted to a wall or other vertical surface during installation of an in-floor heating system.

As shown, the temporary mounting member <NUM> includes a through hole <NUM>. During installation of an in-floor heating system, a nail, screw, peg, or other temporary attachment device may be inserted into a wall and used to hang the housing <NUM> in a desired location via through hole <NUM>. Alternatively, the housing <NUM> may be disposed on a surface such as a counter top, floor, or shelf.

The housing <NUM> of the adapter device <NUM> further includes the heating element coupling section <NUM> disposed at least in part on the third sidewall <NUM>-<NUM> of the housing <NUM>. The heating element coupling section <NUM> is configured to allow for temporary electrical interconnection between the second terminal block <NUM>-<NUM> and the heating element <NUM>, for example.

As shown more clearly in <FIG>, the heating element coupling section <NUM> is also provided at in part by a door/cover <NUM> disposed adjacent the sixth sidewall <NUM>-<NUM> of the housing <NUM>. Preferably, the door/cover <NUM> provides at least a portion of the sixth sidewall <NUM>-<NUM>. The door <NUM> includes a one or more (e.g., a plurality of) apertures/through holes <NUM> (See <FIG>) configured to allow, for example, <NUM> or <NUM> AWG wire to extend therethrough and electrically couple with the second terminal block <NUM>-<NUM>. Preferably, each of the apertures <NUM> are configured to allow at least one conductor wire and/or associated sheath to extend therethrough.

As further shown in <FIG>, the door <NUM> can include a hinge <NUM> to rotatably couple to the housing <NUM>. The door <NUM> can further include tensioning member <NUM>, e.g., a screw. The tensioning member <NUM> can be configured to selectively set/apply a bias force supplied against the door <NUM> and towards the housing <NUM>. The door <NUM> may therefore be selectively tensioned via tensioning member <NUM> to provide strain relief for wires/cabling of the mat <NUM> coupled to the heating element coupling section <NUM>. The door <NUM> may therefore provide both strain relief for the wires/cabling to the heating element <NUM>, and comport with various safety requirements/standards that stipulate covering/shielding conductor wires to avoid incidental contact between conductor wires and users/installers.

Returning to <FIG>, the thermostat coupling section <NUM> is provided adjacent the second sidewall <NUM>-<NUM>. The thermostat coupling section <NUM> may also be referred to herein as a thermostat mounting section/region, a control unit mounting region, or simply a mounting region. The thermostat coupling section <NUM> can include a cavity/recess <NUM>. The cavity <NUM> is defined at least in part by a recessed surface <NUM> that is offset from the second sidewall <NUM>-<NUM>, and that extends substantially parallel with the second sidewall <NUM>-<NUM>. The cavity <NUM> is further defined by an interior sidewall <NUM> that extends between and adjoins the recessed surface <NUM> and the second sidewall <NUM>-<NUM>.

The cavity <NUM> can be configured to at least partially receive a portion of the thermostat <NUM> (e.g., implemented as the thermostat <NUM> of <FIG>) and/or a thermostat base coupled thereto (not shown). As further shown in <FIG>, the second sidewall <NUM>-<NUM> can provide one or more threaded inserts/recesses disposed adjacent the cavity <NUM>. The threaded recesses can be utilized to securely couple the base <NUM> (<FIG>) to the housing <NUM>, e.g., using screws <NUM>. Once securely attached, a thermostat such as the thermostat <NUM> (See <FIG>) may then be coupled to the housing <NUM> by way of the thermostat base <NUM>, although this disclosure is not limited in this regard and the thermostat <NUM> may be configured to directly couple to the housing <NUM> of the adapter device <NUM>, e.g., without an intermediate component such as the thermostat base <NUM>.

As shown, the cavity <NUM> further includes a second switch <NUM>-<NUM> and a plurality of pins <NUM> disposed on/adjacent the recessed surface <NUM>. The second switch <NUM>-<NUM> is preferably disposed in substantially the center of the thermostat coupling section <NUM>, and more particularly, substantially the center of the recessed surface <NUM> of the cavity <NUM>, although the second switch <NUM>-<NUM> can be disposed at other locations/surfaces within the cavity <NUM> with minor modification. Likewise, the second switch <NUM>-<NUM> may comprise two or more switches within the cavity <NUM> to minimize or otherwise reduce the potential for accidently energizing pins <NUM> with AC power without the thermostat <NUM> attached/coupled.

The plurality of pins <NUM>, which may also be referred to as electrical interconnects, allow for electrically coupling the adapter device <NUM> with the thermostat <NUM>, and to supply the power signal <NUM> (See <FIG>) to the thermostat <NUM>. In an embodiment, the plurality of pins <NUM> may each comprise, for example, spring-based pogo pins. Each pin of the plurality of pins <NUM> can include a first section (or portion) that extends substantially transverse from the recessed surface <NUM> into the cavity <NUM> to make electrical connection with mating pins of the thermostat <NUM>. A second section of each pin of the plurality of pins <NUM> can extend into the housing <NUM> to electrically couple to, for instance, associated circuitry within the housing <NUM> such as the safety interlock <NUM> (See <FIG>). Alternatively, or in addition, other types of temporary electrical interconnects may be utilized and this disclosure is not limited to utilizing pins/pogopins to temporarily electrically couple the adapter device <NUM> with the thermostat <NUM>.

Note, one or more pins of the plurality of pins <NUM> may also be utilized as momentary switches (also referred to as micro switch interrupts) with a normally-open state that prevents/interrupts electrical communication between the thermostat <NUM> and/or heating element <NUM> in response to the thermostat <NUM> being decoupled from the housing <NUM> of the adapter device <NUM>. Therefore, one or more pins of the plurality of pins <NUM> operating as momentary switches may be utilized to replace the second switch <NUM>-<NUM>, or be utilized in combination with the second switch <NUM>-<NUM>. In any such cases, the safety interlock <NUM> as discussed above may utilize one or more of the pins <NUM> as the aforementioned micro switch interrupts to block and/or disrupt AC power to the thermostat <NUM> and/or heating element <NUM> to further increase safety.

As shown in <FIG>, the thermostat <NUM> removably couples to the adapter device <NUM> at least in part based on at least a portion of the thermostat <NUM> being received in the cavity <NUM> (See <FIG>). In response to the thermostat <NUM> coupling via cavity <NUM>, the thermostat <NUM> actuates the second switch <NUM>-<NUM> to transition the same from an open state to a closed state, e.g., based on the portion of the thermostat <NUM> received within the cavity <NUM> displacing the second switch <NUM>-<NUM>. Note, in instances where the thermostat <NUM> couples to the adapter device <NUM> via a thermostat base, e.g., thermostat base <NUM>, a portion of the thermostat base received within the cavity <NUM> may therefore cause displacement of the second switch <NUM>-<NUM>.

In any such cases, the second switch <NUM>-<NUM> may therefore be configured to transition from the open state to the closed state in response to a user-supplied force introduced by a user coupling the thermostat <NUM> into the cavity <NUM> of the housing <NUM>, and thus by extension, displacing/biasing the second switch <NUM>-<NUM> towards the rear of the housing <NUM>, e.g., the sixth sidewall <NUM>-<NUM>.

The thermostat <NUM> electrically couples to the adapter device <NUM> via mating pads/terminals (not shown) disposed on the thermostat <NUM> that align and engage (directly) with the pins <NUM> in response to the thermostat <NUM> coupling to the adapter device <NUM>, e.g., via cavity <NUM>. The thermostat <NUM> may then be referred to as in a connected state when removably coupled to the adapter device <NUM> via the thermostat mounting region <NUM>, such as shown in <FIG>. On the other hand, the thermostat <NUM> may be referred to as in a disconnected state when decoupled from the thermostat mounting region <NUM> of the adapter device <NUM>. The pins <NUM> may engage the thermostat <NUM> (e.g., via the mating pads/terminals) before the second switch <NUM>-<NUM> transitions from the open state to the closed state.

Turning specifically to <FIG>, the housing <NUM> of the adapter device <NUM> includes the first switch <NUM>-<NUM> disposed on the first sidewall <NUM>-<NUM>. Preferably, the first switch <NUM>-<NUM> is disposed on the first sidewall <NUM>-<NUM> as shown in <FIG>, with the first sidewall <NUM>-<NUM> extending substantially transverse relative to the second sidewall <NUM>-<NUM> that provides the thermostat coupling section <NUM> (See <FIG>). However, the first switch <NUM>-<NUM> may be disposed on other locations/sidewalls of the housing <NUM> with minor modification.

In an embodiment, the first switch <NUM>-<NUM> can comprise a switch, button, or any other suitable device capable of receiving user input and converting the same into mechanical actuation, an electrical signal, or a combination thereof. For example, the first switch <NUM>-<NUM> can be implemented as a touch-sensitive switch that can detect the presence of a finger or a pointer of a user, e.g., a stylus. In an embodiment, the first switch <NUM>-<NUM> comprises a momentary switch that is spring-loaded via a spring member (not shown) or otherwise configured to automatically transition from a closed state to an open state in the absence of a user-supplied force. Preferably, the first switch <NUM>-<NUM> is configured to mechanically interrupt electrical communication between the heating element <NUM> and the AC power source providing the power signal <NUM>, or the thermostat <NUM> and the AC power source providing the power signal <NUM>, or both.

The first switch <NUM>-<NUM> may therefore be configured to provide the power signal <NUM> received from an AC power source to the heating element <NUM> (<FIG>) and/or thermostat <NUM> for a predetermined period of time that is preferably user selected and equal to a period of time starting from when a user-supplied force is first present/applied to the first switch <NUM>-<NUM> to the moment the user-supplied force is no longer supplied, e.g., based on a user lifting their finger from the first switch <NUM>-<NUM>.

Note, as discussed further below, the predetermined amount of time before disrupting power may also be set by the controller <NUM> (or other suitable controller such as provided by the remote computing device <NUM>) when performing tests such as overcurrent detection. Accordingly, and in an embodiment, the user may continue to actuate the first switch <NUM>-<NUM> with their finger, but the controller <NUM> may decouple the power signal <NUM> of the AC power source from the heating element <NUM> via switch <NUM>, for instance, after a predetermined amount of time that allows for energizing of the heating element <NUM> and electrical measurements of the same to be performed, e.g., <NUM> to <NUM> seconds.

Returning to <FIG>, the thermostat <NUM> receives the power signal <NUM> via a port/socket provided by AC coupling section <NUM>, for example, and utilizes the same to supply power to components of the thermostat <NUM> such as the display <NUM>. In this energized scenario, the thermostat <NUM> may therefore be referred to as in a powered state. In some cases, and as discussed below with regard to the process <NUM> of <FIG>, the thermostat <NUM> receives power in response to the actuation of the first and/or second switches <NUM>-<NUM>, <NUM>-<NUM>. For instance, the second switch <NUM>-<NUM> can be actuated in response to the thermostat <NUM> being coupled into the cavity <NUM>, as discussed above. In addition, the first switch <NUM>-<NUM> can be actuated based on, for instance, a user-supplied force being applied thereto.

In any such cases, the thermostat <NUM> can visualize an operational state of the adapter device <NUM> and associated components via a user interface rendered on display <NUM> when in the aforementioned connected and powered state (e.g., when coupled to the adapter device <NUM> and energized). For example, the operational state can include a value representing a current temperature of the in-floor heating element (See <FIG>), e.g., based on a temperature sensor (not shown) disposed adjacent heating element <NUM> and electrically coupled to backplane circuitry within the adapter device <NUM>. Note, the temperature sensor may be wirelessly coupled to the thermostat <NUM> via NIC <NUM>, for example, to reduce the necessity of routing wires within the floor.

Other examples of an operational state can include one or more measured electrical characteristics of the power signal <NUM> of the AC source, and/or of the current drawn by the heating element <NUM>. Still other examples of an operational state include an indication of a fault introduced during installation of an in-floor heating element. For instance, damage to a coil within the heating element <NUM> may be detected based on a resistance/voltage change measured by the power measurement circuitry <NUM> implementing the example line-fault test circuit <NUM> of <FIG>. In response, the thermostat <NUM> may visualize an indication of the fault via the display <NUM>, and/or emit an audible tone via speaker <NUM>.

Also in the connected and powered state, the thermostat <NUM> can detect the presence of the adapter device <NUM>, e.g., as opposed to other devices such as a thermostat base or backplane without the adapter device <NUM> coupled thereto, and in response to detecting the presence of the adapter device <NUM> visualize or otherwise enable one or more diagnostic and testing processes. The thermostat <NUM> may detect the presence of the adapter device <NUM> via, for instance, electrical communication with the adapter device <NUM> (e.g., a data bus) or simply through a configurable setting stored in the memory <NUM>.

Continuing on, and in response to the thermostat <NUM> detecting the same is coupled to the adapter device <NUM>, the thermostat <NUM> may then cause display <NUM> to show a user interface substantially similar to that of the user interface <NUM> shown in <FIG>. Likewise, the mobile computing device <NUM> can receive a message/packet from the thermostat <NUM> via RF signal <NUM> that causes the mobile computing device <NUM> to visualize or otherwise enable access to the features shown via user interface <NUM>.

A user/installer may then select one or more user interface elements of the user interface <NUM> to initiate a desired test mode. For example, test modes can comprise at least one of a voltage test to identify a voltage mismatch condition (also referred to herein as a voltage rating mismatch) between the power signal <NUM> of the AC power source and the heating element <NUM> and/or thermostat <NUM> based on a predetermined voltage rating for the heating element <NUM> stored in the memory <NUM>, and/or an overcurrent test to energize the heating element <NUM> and detect if the same is drawing a current greater than a maximum predetermined current for the heating element <NUM> stored in the memory <NUM>. The result(s) of the initiated tests may then be visualized via display <NUM> and/or the mobile computing device <NUM> as, for instance, a pass/fail indicator <NUM> (See <FIG>). Alternatively, or in addition, the thermostat <NUM> sends the result(s) of the initiated tests to a remote computer server, e.g., via NIC <NUM>, for technical support and quality control, as discussed above.

In view of the foregoing, the first switch <NUM>-<NUM> may therefore be momentarily actuated (e.g., by a finger of a user) to cause the power signal <NUM> to be supplied to the thermostat <NUM> to ensure that certain operations/modes, such as energizing the heating element <NUM>, can be immediately disrupted/stopped to avoid damage to the heating element <NUM> and/or to minimize or otherwise reduce the chance of a potentially fatal electric shock. In one embodiment, the first switch <NUM>-<NUM> is configured to automatically cause the thermostat <NUM> to initiate one or more tests without necessarily requiring a user to initiate the tests via display <NUM> of the thermostat <NUM> or via the app of the mobile computing device <NUM>.

Alternatively, or in addition, the first switch <NUM>-<NUM> is configured to cause maintained execution of one or more selected tests. For instance, the first switch <NUM>-<NUM> may be configured to mechanically toggle between two positions, e.g., an ON and an OFF position. However, it should be noted that the first switch <NUM>-<NUM> may be configured to support a range of actuation modes to allow for certain operations, e.g., such as energizing the heating element <NUM>, to be momentary while others such as WiFi diagnostics to be maintained without a user supplying a force or otherwise maintaining contact with the first switch <NUM>-<NUM>.

As discussed above, the system <NUM> can include power measurement and monitoring circuitry <NUM> implemented within the thermostat <NUM>. <FIG> shows one example current measurement circuit (or ammeter circuit) <NUM> suitable for use in the power measurement and monitoring circuitry <NUM>. The ammeter circuit <NUM> allows for a load drawn by a heating element, e.g., heating element <NUM>, to be measured and output as a proportional electrical signal for diagnostic and/or historical power monitoring and tracking purposes.

The ammeter circuit <NUM> includes an input stage <NUM>. The input stage <NUM> includes a terminal coupled to Vcc, e.g., coupled to a terminal of the second terminal block <NUM>-<NUM> providing conductor L1 or L2 (See <FIG>). The input stage <NUM> further includes a sensor <NUM> implemented as a hall effect sensor to ensure electrical isolation between high and low-power sides. The input stage <NUM> then outputs, for instance, a low-voltage sinewave (e.g., 1V peak-to-peak) that proportionally represents an amount of current measured by the sensor <NUM>. The low-voltage sinewave may also be referred to herein as a measured current waveform/signal.

The amplifier stage <NUM> includes an input coupled to the output of the input stage <NUM> to receive the measured current signal. The amplifier stage <NUM> includes an operational amplifier arrangement with a first input terminal electrically coupled to the input of the amplifier stage <NUM> to receive the measured current signal. The operational amplifier arrangement further includes a second input terminal coupled to a reference signal. The operational amplifier arrangement determines and amplifies a difference between the reference signal and the measured current signal. The amplifier stage includes a filter network comprising one or more filtering capacitors to, for instance, reject various unwanted high and/or low frequencies from the measured current signal. The operational amplifier arrangement then outputs a signal representing the determined differential.

The output stage <NUM> includes a first end electrically coupled to the output of the amplifier stage <NUM> to receive the signal representing the determined differential. The output stage <NUM> further includes a filter network comprising one or more filtering capacitors to for instance, reject various unwanted high and/or low frequencies from the signal representing the determined differential. The output stage <NUM> then outputs a signal representing a measured current drawn by the heating element <NUM>. The controller <NUM> may then derive an electrical current value, e.g., in Amperes (A), based on the signal output stage <NUM> utilizing, for example, optional post-processing routine. However, the controller <NUM> may derive the measured current value through a relatively simple analog to digital conversion without necessarily modifying or otherwise performing post-processing on the signal from the output stage <NUM>.

Note, the ammeter circuit <NUM> is preferably isolated from the primary voltage and current that is flowing through the heating element control circuit <NUM> to the heating element <NUM>. To achieve isolation, the ammeter <NUM> can utilize a linear Hall Effect sensor that measures the magnetic field given off by the current that is flowing through the high voltage/high current trace/terminal to the heating element <NUM>. However, other sensor types are also within the scope of this disclosure.

Continuing with <FIG>, the ammeter circuit <NUM> can include an optional temperature compensation stage <NUM> that electrically couples between output stage <NUM> and the controller <NUM>. The optional temp compensation stage <NUM> can include a thermistor TH1 for temperature compensation purposes. Through experimentation and measurement, this disclosure has identified that the output stage <NUM> can output a signal to the controller <NUM> with variation tied to operating temperatures within, for instance, housing <NUM> (<FIG>) or other associated enclosure.

Experiments were conducted with operating temperatures set at specific targets that included -<NUM>, <NUM> and <NUM>. With -<NUM> being selected as a target below UL requirements, and <NUM> being selected to represent high temperature environments. During the experiments, a heating element rated for <NUM> amperes was electrically coupled to an AC source and measured by the ammeter circuit <NUM> disposed within a housing and having an ambient temperature therein set to each of the aforementioned operating temperatures. Table <NUM> provided below summarizes the findings at each operating temperature target.

As shown above, ambient operating temperature significantly varied the current measurement output by the ammeter circuit <NUM> across a range of loads introduced by the heating element. For instance, loads of 8A introduced a measurement variance of about <NUM>. 3V between operating temperatures of -<NUM> and <NUM>. Therefore, the optional temperature compensation stage <NUM> may be utilized to reduce temperature sensitivity and improve accuracy in a range of ambient operating temperatures.

The ammeter circuit <NUM> optionally implements a flux concentrator to increase measurement sensitivity and reduce noise. <FIG> shows an example flux concentrator <NUM> suitable for use in the ammeter circuit <NUM> of <FIG>. As shown, the flux concentrator <NUM> may comprise two substantially L-shaped pieces/sections (also referred to herein as concentrator members), namely first and second concentrator members <NUM>-<NUM>, <NUM>-<NUM>, respectively, that couple together physically and electrically at coupling section <NUM>. The coupling section <NUM> can include, for instance, tape or other suitable approach to couple the concentrator members together.

Each of the first and second concentrator members <NUM>-<NUM>, <NUM>-<NUM> include a stem, e.g., stems <NUM>-<NUM> and <NUM>-<NUM> respectively, and an arm that extends substantially transverse relative to the stem, e.g., at an angle of <NUM>-<NUM> degrees, and preferably an angle of <NUM> degrees. The stem and arm of each of the first and second concentrator members <NUM>-<NUM>, <NUM>-<NUM>, extend substantially parallel with each other, such as shown in <FIG>. The arm of each of the first and second concentrator members <NUM>-<NUM>, <NUM>-<NUM> extends an overall length of L3 from an associated stem, with L3 measuring about <NUM>-<NUM>, and preferably <NUM>, for example.

As further shown more clearly in <FIG>, each concentrator member can include a stem <NUM>-N having an overall length of L4, with L4 measuring <NUM>-<NUM>, and preferably <NUM>, although other lengths are within the scope of this disclosure. In addition, each arm <NUM>-N can include an overall length of L5, with L5 measuring between <NUM>-<NUM>, for example. The overall width W1 of arm <NUM>-N can measure <NUM>-<NUM>, for example. Each of the arm <NUM>-N and stem <NUM>-N can include an overall thickness W2 of between <NUM>-<NUM>, for example.

Returning to <FIG>, an end of each arm can include a bent/angled portion to extend into, or otherwise be in operable proximity of, flux sensing region <NUM>. The flux sensing region <NUM> allows for magnetic flux to concentrate for detection purposes by sensor <NUM>.

Each arm includes an offset distance of D1 relative to the mounting surfaces of a substrate <NUM> to minimize or otherwise reduce electrical interference. The substrate <NUM> comprises, for instance, a printed circuit board (PCB) or other suitable substrate for mounting of electrical components and traces. The offset distance D1 between the arms of the flux concentrator <NUM> and the substrate <NUM> measures <NUM>, for example, although other offset distances are within the scope of this disclosure. Accordingly, components such as copper traces <NUM> that are disposed on opposite mounting surfaces provided by the substrate <NUM> can be electrically isolated from the arms of the flux concentrator <NUM> based at least in part on the offset distance D1.

As further shown in <FIG>, the stem <NUM>-<NUM> of the first concentrator member <NUM>-<NUM> extends at least partially through the substrate <NUM>. This advantageously allows for each arm of the concentrator members to be disposed adjacent opposite sides of the substrate <NUM>, and by extension, in a manner that provides the sensing region <NUM> with concentrated magnetic flux/energy. In addition, this allows for the flux concentrator <NUM> to securely couple to the substrate <NUM>, e.g., based on a friction fit with the substrate <NUM> and/or via an adhesive such as epoxy.

The multi-member (or multi-piece) configuration of the flux concentrator <NUM> also allows for simplified manufacturing processes. For instance, the first and second concentrator members <NUM>-<NUM>, <NUM>-<NUM> of the flux concentrator <NUM> may be installed in a multi-step process that includes, for instance, inserting the first concentrator member <NUM>-<NUM> through the substrate <NUM>, and then subsequently coupling the second concentrator member <NUM>-<NUM> to the first concentrator member <NUM>-<NUM>, e.g., via tape or other approach at coupling section <NUM>. The through-hole/aperture (not shown) of the substrate <NUM> can include a profile that corresponds to the shape/profile of the flux concentrator <NUM>, e.g., a substantially rectangular profile.

Thus, the aperture (not shown) of the substrate <NUM> provides a mechanical alignment member to ensure the stem and arm of the first concentrator member <NUM>-<NUM> is aligned and oriented with sensor <NUM> in a manner that disposes an arm of the same within operable proximity of the flux sensing region <NUM>. In addition, the first concentrator member <NUM>-<NUM> coupled to the substrate <NUM> provides a second mechanical alignment member/feature for coupling of the second concentrator member <NUM>-<NUM>. For instance, the multi-step process can then include coupling the second concentrator member <NUM>-<NUM> to the first concentrator member <NUM>-<NUM> in a stack/sandwich configuration that automatically aligns and orients the second concentrator <NUM>-<NUM> in a manner that disposes an associated arm in operable proximity with the flux sensing region <NUM>, such as shown in <FIG>.

<FIG> shows another example of a flux concentrator <NUM>' suitable for use in the ammeter circuit <NUM> of <FIG>. As shown, the flux concentrator <NUM>' can be formed from a single, monolithic piece of material. The flux concentrator <NUM>' comprises electrical-insulating but magnetically-conductive material such as ferrite.

<FIG> shows one example voltage measurement circuit (or voltage monitoring circuit) <NUM> suitable for use in the power measurement and monitoring circuitry <NUM>. The voltage monitoring circuit <NUM> provides a relatively simple arrangement that detects if the heating element control circuit <NUM> is coupled to <NUM> Vac or <NUM>/<NUM> Vac, for example.

As shown, the voltage monitoring circuit <NUM> includes a high-power input stage <NUM> that includes terminals electrically coupled to conductors L1 and L2, e.g., via the second terminal block <NUM>-<NUM> (See <FIG>). Conductors L1 and L2 are configured to communicate a signal having 120Vac or 220Vac, depending on a desired configuration. The high-power input stage <NUM> further includes an integrated circuit (IC) configured to electrically isolate the conductors L1 and L2 from a low-power output stage <NUM>. As shown, the IC can be implemented as an optoisolator that provides a two-state, low-voltage output signal, e.g., <NUM>-5V, inversely related to the voltage potential applied at the high-power input stage <NUM>.

Thus, when the high-power stage is coupled to 120Vac the output of the IC and low-power output stage <NUM> is a solid high (also referred to herein as a first voltage level) with effectively zero ripple, e.g., 12Vdc or ~<NUM>. The output from the low-power output stage <NUM> then begins to drop when the input voltage reaches ~<NUM> Vac. From <NUM> Vac and lower, the low-power output stage <NUM> outputs a signal that stabilizes at a low voltage (also referred to herein as a second voltage level) measuring between <NUM>. 5Vdc and 1Vdc, e.g., when AC power is measured at room temperature (e.g., about <NUM>-<NUM> degrees Celsius). Thus, the voltage monitoring circuit <NUM> allows for simple detection of 120Vac versus 220Vac (or 240Vac) through a course-grain comparison that allows for detecting the presence of a first predetermined voltage (e.g., <NUM> Vac) from a second predetermined voltage (e.g., <NUM>/240Vac) based on the output signal providing a high and low value in the form of the above-mentioned first and second voltage levels.

The output signal of the low-power output stage <NUM> may therefore output between a high and low Vdc value to provide a logical HIGH and LOW value to the controller <NUM>, respectively. Preferably, the low-power output stage <NUM> is configured to output a signal between <NUM>. 5Vdc and <NUM>. 3Vdc which allows for electrical interconnection with terminals of the controller <NUM> without the necessity of step-down/power conversion circuitry. However, other voltage values for the low-power output stage <NUM> are also within the scope of this disclosure such as 0Vdc to 12Vdc.

In an embodiment, temperature compensation may also be applied to the output signal of the low-power output stage <NUM>. For example, as shown in Table <NUM>, experimental results at various operating temperature set points demonstrates the temperature-dependence of the output signal from the low-power output stage <NUM>.

<FIG> shows one example of a line-fault test circuit <NUM> suitable for use in the power measurement and monitoring circuitry <NUM>. The line-fault test circuit <NUM> couples to terminals of the heating element <NUM>, e.g., L1 and L2 via the second terminal block <NUM>-<NUM> (<FIG>), and can detect a break along the heating element <NUM>, e.g., due to damage during installation and/or mechanical defect in the heating element <NUM>.

As shown, the line-fault test circuit <NUM> operates on a battery source <NUM>, and preferably, a <NUM>. 3V coin cell battery. The line-fault test circuit <NUM> is configured to pulse at a predetermined interval, e.g., every <NUM>-<NUM> seconds, and supply a relatively low voltage signal (also referred to herein as a test voltage or test signal) to the heating element <NUM> via conductors L1 and L2, e.g., a <NUM>. 3v signal or less. Each pulse lasts for a predetermined period of time, e.g., between <NUM>-<NUM>. The pulses may be achieved by capacitor <NUM> that operates as an oscillator.

In the event of a fault condition, e.g., a break within heating element <NUM>, the line-fault test circuit <NUM> is configured to detect the same and cause an audible tone (e.g., via a piezo buffer and/or speaker <NUM> of <FIG>) to be emitted. In addition, the line-fault test circuit <NUM> can drive one or more LEDS (e.g., D4) to visually indicate the present of the fault, e.g., through blinking or solid LED illumination. The line-fault test circuit <NUM> further includes test button <NUM> to simulate fault conditions and confirm proper operation of the line-fault test circuit <NUM>.

Note, the following momentary test process can be preceded by a registration sequence that allows a user/installer to register a thermostat, e.g., thermostat <NUM> (See <FIG>), with a manufacturer via an "App" executed on the mobile computing device <NUM>. For example, the mobile computing device <NUM> may utilize an integrated camera sensor to "scan" a fiducial such as QR code disposed on the thermostat <NUM> and/or provided with the thermostat <NUM> via printed documentation. In response to detecting the fiducial, the mobile computing device <NUM> may utilize the same to determine an identifier (also referred to herein as a unique identifier) for the thermostat <NUM> and provide the same to a remote host, e.g., a computer server operated by the manufacturer accessible via the Internet. In addition, the app of the mobile computing device <NUM> may also be utilized by a user/installer to scan a fiducial (e.g., a QR code) of an in-floor heating element, for example, to determine electrical characteristics associated with the same. The electrical characteristics can comprise, for example, a voltage rating (e.g., 120Vac, or 220Vac) and maximum current rating.

The mobile computing device <NUM> may then store various settings and parameters in a database of the remote computer server (e.g., using the identifier) such as the voltage rating and/or maximum current rating for the heating element <NUM>. Alternatively, or in addition, the various settings and parameters may also be stored in the memory <NUM> of the thermostat <NUM> using, for instance, messaging provided via RF signals <NUM>, and/or through a user interface provided by the display <NUM>.

<FIG> collectively show a momentary test process <NUM> that exemplifies various aspects and features of the present disclosure. The momentary test process <NUM> can be performed by the controller <NUM> of the thermostat <NUM> (See <FIG>), although this disclosure is not intended to be limited in this regard. For example, an "app" executed on a mobile computing device, e.g., such as mobile computing device <NUM>, may be configured to perform various acts of the momentary test process <NUM> alone or in combination with controller <NUM>.

The process <NUM> starts in act <NUM>. In act <NUM>, the controller <NUM> receives a user request to initiate a momentary test. The controller <NUM> receives the request via, for instance, a command received from the mobile computing device <NUM> by way of NIC <NUM> (See <FIG>). Alternatively, the controller <NUM> receives the user request based on a user/installer supplying a force to actuate the first switch <NUM>-<NUM>. Preferably, the controller <NUM> receives the user request based on actuation of both the first and second switches <NUM>-<NUM>, <NUM>-<NUM>.

Note, actuation of the first and/or second switches <NUM>-<NUM>, <NUM>-<NUM> can cause the thermostat <NUM> to receive power (e.g., via an AC power source external to the thermostat <NUM>) to energize components of the thermostat <NUM>, e.g., the display <NUM>, the controller <NUM>, the NIC <NUM>, the power measurement circuitry <NUM>, without necessarily energizing the heating element <NUM>. Accordingly, the controller <NUM> may also receive the user request to initiate the momentary test in act <NUM> after a user selects one or more menu/feature options via energized display <NUM>, for example.

In act <NUM>, the controller <NUM> measures the voltage of an AC power signal (e.g., power signal <NUM>) using, for example, the voltage monitoring circuit <NUM> of <FIG>. In act <NUM>, the controller <NUM> compares the measured voltage to a predetermined voltage rating associated with the heating element <NUM>. The controller <NUM> retrieves the predetermined voltage rating from, for example, the memory <NUM> or from another location such as a remote host/server that maintains the settings in a database that associates an identifier associated with the thermostat <NUM> with various settings and preferences, as discussed above.

In act <NUM>, the controller <NUM> determines whether the measured voltage equals the predetermined voltage (e.g., is within an acceptable range defined by the predetermined voltage) retrieved in act <NUM>. For example, the measured voltage may indicate a <NUM> Vac source and the predetermined voltage may be equal to 120Vac. If the measured voltage received in act <NUM> matches the predetermined voltage setting retrieved in act <NUM>, the process continues to <NUM>. Otherwise, the process continues to act <NUM>.

In act <NUM>, the controller <NUM> determines if the measured voltage is less than or equal to a maximum heating element voltage for the heating element <NUM>. A value/setting representing the maximum heating element voltage may be stored in the memory <NUM> of the thermostat <NUM>, and/or in a remote computer server as discussed above. If the measured voltage is less than or equal to the maximum heating element voltage, the process <NUM> continues to act <NUM>. Otherwise, the process <NUM> continues to act <NUM>. In act <NUM>, the controller <NUM> optionally indicates the error condition to the user via display <NUM> (<FIG>), and/or via the user interface <NUM> of the mobile computing device <NUM>. The process <NUM> then ends.

In act <NUM>, the controller <NUM> determines if the thermostat <NUM> is attached/coupled to an adapter device, e.g., the adapter device <NUM> (See <FIG>). Stated differently, in act <NUM>, the controller <NUM> determines if the thermostat <NUM> is coupled to only a standard base/dock, e.g., thermostat base <NUM>, or if the thermostat <NUM> is coupled to an adapter device consistent with the present disclosure. In an embodiment, the controller <NUM> determines whether the thermostat <NUM> is coupled to an adapter device based on a setting or other identified stored in the memory <NUM>, for example. If the thermostat <NUM> is attached to an adapter device, the process <NUM> continues to act <NUM>. Otherwise, the process continues to act <NUM> and the controller <NUM> optionally indicates the error condition to the user via display <NUM> (<FIG>), and/or via the user interface <NUM> of the mobile computing device <NUM>. The process <NUM> then ends.

In act <NUM>, the controller <NUM> energizes the heating element <NUM> by providing a signal to the heating element control circuit <NUM>. In response, the heating element control circuit <NUM> transitions the switch <NUM> to a closed state to electrically couple the heating element <NUM> with the power signal <NUM> of the AC power source, e.g., via conductors L1 and L2.

In act <NUM>, the controller <NUM> measures current drawn via the heating element <NUM> using the ammeter circuit <NUM> of <FIG>, for example. Also in act <NUM>, the controller <NUM> optionally determines whether the OIC <NUM> (See <FIG>) is in an overcurrent fault state or a normal state. If the OIC <NUM> is in an overcurrent fault state, the controller <NUM> optionally indicates the error condition to the user via display <NUM> (<FIG>), and/or via the user interface <NUM> of the mobile computing device <NUM>, and the process <NUM> then end. Otherwise, the process <NUM> continues to act <NUM>.

In act <NUM>, the controller <NUM> determines whether the current measured in act <NUM> is approximately equal to the rated heating element current (also referred to herein as a predefined current). A value/setting representing the rated heating element current may be stored in the memory <NUM> of the thermostat. Otherwise, the process <NUM> continues to act <NUM>.

In act <NUM>, the controller <NUM> de-energizes the heating element <NUM> by, for example, providing a signal (or a lack thereof) to the heating element control circuit <NUM> to cause the same to switchably decouple the heating element <NUM> from the power signal <NUM> of the AC power source. This can include the heating element control circuit <NUM> providing a signal to switch <NUM>, with the signal causing the switch <NUM> to transition to an open state to cause the heating element <NUM> to electrically decouple from the power signal <NUM> of the AC power source. The process <NUM> then continues to act <NUM> and the controller <NUM> optionally indicates the error condition to the user via display <NUM> (<FIG>), and/or via the user interface <NUM> of the mobile computing device <NUM>. The process <NUM> then ends.

In act <NUM>, the controller <NUM> de-energizes the heating element <NUM> as discussed above in act <NUM>. In act <NUM>, the controller <NUM> indicates the momentary test was successful to the user via display <NUM> (<FIG>), and/or via the user interface <NUM> of the mobile computing device <NUM>. The process <NUM> then ends.

In accordance with an aspect, the present disclosure may feature an adapter device to removably couple to a thermostat and provide temporary electrical interconnection between the thermostat, an in-floor heating element, and an AC power source during installation and testing of the in-floor heating element. The adapter device may include a housing, a heating element interconnect disposed on the housing to electrically couple to an in-floor heating element, an alternating current (AC) power source interconnect coupled to the housing to electrically couple with an AC power source to receive a power signal, a thermostat mounting region defined by the housing to removably couple to the thermostat, and a first switch coupled to the housing. The thermostat mounting region may include at least one electrical interconnect to electrically couple to the thermostat. The first switch may have a closed state to electrically couple the received power signal to the thermostat and/or the in-floor heating element, and an open state to electrically decouple the received power signal from the thermostat and/or the in-floor heating element. The first switch may be configured to receive a user-supplied force, and in response to receiving the user-supplied force, transition to the closed state to cause the in-floor heating element to energize via the received power signal.

The first switch may be configured to mechanically interrupt electrical communication between at least the in-floor heating element and the AC power source in response to being transitioned to the open state. For example, the first switch may be configured to mechanically interrupt electrical communication between the in-floor heating element and the AC power source, and the thermostat and the AC power source, in response to being transitioned to the open state. The first switch may include a button configured to be displaced by the user-supplied force to transition the first switch to a closed state. The button of the first switch may include a spring member to cause the first switch to transition from the closed state to the open state in response to an absence of the user-supplied force. The first switch may be coupled to a first sidewall of the housing. The thermostat mounting region may be defined by at least a second sidewall of the housing. The first sidewall may extend substantially transverse relative to the second sidewall of the housing.

The first switch may be configured to electrically couple the received power signal to the thermostat in response to the first switch transitioning from the open state to the closed state. The first switch may be configured to electrically couple the received power signal to the thermostat and the in-floor heating element in response to the first switch transitioning from the open state to the closed state. The first switch may be provided by the at least one electrical interconnect of the thermostat mounting region. The first switch may be configured to receive the user-supplied force to transition to the closed state based on a user coupling the thermostat to the thermostat mounting region and displacing the first switch with a portion of the thermostat and/or a portion of a thermostat base of the thermostat. The first switch may be configured automatically transition to the open state in response to the thermostat being decoupled from the thermostat mounting region.

The adapter device may further include a second switch coupled to the housing. The second switch may be configured to transition between a closed state and an open state, the closed state to electrically couple the received power signal to the thermostat and/or the in-floor heating element, and an open state to electrically decouple the received power signal from the thermostat and/or the in-floor heating element. The second switch may include a momentary switch. The second switch may include a pogo pin. The second switch may be disposed at a center of the thermostat mounting region. The second switch may be provided at least in part by the at least one electrical interconnect of the thermostat mounting region.

The first and second switches may collectively provide a safety interlock. The safety interlock may be configured to prevent electrical coupling between the received power signal and the thermostat based at least in part on the first and/or second switch.

The first and second switches may collectively provide a safety interlock, the safety interlock to prevent electrical coupling between the power signal and the thermostat and/or between the power signal and the in-floor heating element based at least in part on the first and/or second switch.

The thermostat mounting region may define a cavity. The cavity of the thermostat mounting region may be configured to receive at least a portion of the thermostat and/or a thermostat base of the thermostat. At least one electrical interconnect may be disposed in the cavity of the thermostat mounting region. A portion of the at least one electrical interconnect may extend into the cavity. At least one electrical interconnect may be configured to electrically couple to the thermostat in response to the thermostat and/or a thermostat base of the thermostat being at least partially received within the cavity. The at least one electrical interconnect may be a pin that extends substantially transverse from the housing. The at least one interconnect may be a pogo pin.

The AC power source interconnect may be configured with a socket to couple to a male or female plug. The socket may be configured to couple to an IEC-<NUM>-C13 or IEC-<NUM>-C14 plug.

The heating element interconnect may include a plurality of terminals for electrically coupling to the in-floor heating element via a plurality of conductor wires. The heating element interconnect may include a door coupled to the housing. The door may at least partially cover the plurality of terminals. The door may define a plurality of apertures, each aperture of the plurality of apertures configured to allow at least one conductor wire of the plurality of conductor wires to extend therethrough and couple to an associated terminal of the plurality of terminals. The door may define a plurality of apertures, each aperture of the plurality of apertures configured to allow at least one conductor wire of the plurality of conductor wires and an associated sheath to extend therethrough. The door may include a tensioning member to adjustably set an amount of bias force supplied against the door and towards the housing. The tensioning member may include a screw. The door may be configured to provide strain relief for the plurality of conductor wires.

The adapter device may further include a relay. The relay may be configured to electrically couple the in-floor heating element to the power signal based at least in part on the first switch being in the closed state. The relay may be disposed in the housing.

The adapter device may further include a temporary mounting member coupled to the housing. The temporary mounting member may be configured to allow the housing to removably couple to a wall or other vertical surface. The temporary mounting member may include a through hole for temporarily coupling the housing to the wall or surface via a temporary attachment device. The temporary attachment device may include a nail, screw, or peg.

In accordance with another aspect, the present disclosure may feature a thermostat for use with at least one in-floor heating element. The thermostat may include a housing, a heating element control circuit coupled to the housing, a first power measurement circuit coupled to the housing, and a controller. The heating element control circuit may be configured to cause an in-floor heating element to electrically couple to an AC power source. The first power measurement circuit may be configured to measure a first electrical characteristic of the in-floor heating element and/or the AC power source. The controller may be configured to receive the first electrical characteristic and detect a fault based on comparing the first measured electrical characteristic to a predefined electrical value.

The controller may be configured to cause the heating element control circuit to switchably decouple the in-floor heating element from the AC power source in response to the detected fault. The controller may be configured to prevent the heating element control circuit from electrically coupling the in-floor heating element to the AC power source in response to the detected fault.

The heating element control circuit may include a relay to switchably electrically couple the in-floor heating element to the AC power source.

The first electrical characteristic measured by the first power measurement circuit may include a voltage of the AC power source or a current drawn by the in-floor heating element.

The first power measurement circuit may be a voltage monitoring circuit. The first measured electrical characteristic may represent a measured voltage of the AC power source. The first power measurement circuit may be configured to output a first voltage signal representing a measured voltage of the AC power source. The first voltage signal may include at least a first voltage level to indicate presence of a first predetermined voltage provided by the AC power source and a second voltage level to indicate a presence of a second predetermined voltage provided by the AC power source. The first predetermined voltage may be <NUM> Volts of alternating current (Vac). The second predetermined voltage may be 220Vac or 240Vac. The first voltage level may be greater than the second voltage level, the first and second voltage levels providing a logical high or low, respectively, for input to the controller.

The thermostat may further include memory to store at least one predefined voltage rating representing a maximum voltage rating for the in-floor heating element. The fault may indicate a voltage rating mismatch between the in-floor heating element and the AC power source. The controller may be configured to detect the voltage rating mismatch based on the measured voltage of the AC power source being different than the predefined voltage rating. The controller may be configured to prevent the heating element control circuit from electrically coupling the in-floor heating element to the AC power source in response to the detected voltage rating mismatch. The thermostat may further include a speaker, and the controller may be configured to cause the speaker to emit an audible tone in response to the detected voltage rating mismatch. The thermostat may further include a network interface circuit (NIC), and the controller may be configured to send a message to a remote computing device via the NIC based on the detected voltage rating mismatch. The thermostat may further include a display, and the controller is configured to cause the display to visualize an indicator based on the detected voltage mismatch.

The first power measurement circuit may be an ammeter circuit, and the first measured characteristic may represent a measured current drawn by the in-floor heating element from the AC power source. The thermostat may further include memory to store at least one predefined current rating that represents a maximum current for the in-floor heating element. The fault may indicate an overcurrent condition of the in-floor heating element, and the controller may be configured to detect the overcurrent condition based on the first measured electrical characteristic indicating the measured current drawn by the in-floor heating element from the AC power source is greater than the predefined current rating. The controller may be configured to electrically decouple the in-floor heating element from the AC power source in response to the detected overcurrent condition. The thermostat may further include a speaker, and the controller may be configured to cause the speaker to emit an audible tone in response to the detected overcurrent condition. The thermostat may further include a network interface circuit (NIC), and the controller may be configured to send a message to a remote computing device via the NIC based on the detected overcurrent condition. The thermostat may further include a display, and the controller may be configured to cause the display to visualize an indicator based on the detected overcurrent condition.

The first power measurement circuit may be a line-fault test circuit configured to electrically couple to first and second terminals of the in-floor heating element and supply a test voltage to the in-floor heating element. The first measured electrical characteristic may be a voltage potential measured between the first and second terminals of the in-floor heating element. The controller may be configured to detect the fault based on the voltage potential, the detected fault indicating an open circuit condition of the in-floor heating element. The thermostat may further include a speaker, and the controller may be configured to cause the speaker to emit an audible tone in response to the detected open circuit condition. The thermostat may further include a network interface circuit (NIC), and the controller may be configured to send a message to a remote computing device via the NIC in response to the detected open circuit condition. The thermostat may further include a display, and the controller may be configured to cause the display to visualize an indicator based on the detected open circuit condition.

The thermostat may further include a second power measurement circuit. The first and second power measurement circuit may be configured to measure different electrical characteristics of the AC power source and/or in-floor heating element. The first power measurement circuit may be disposed in the housing of the thermostat. The thermostat may further include a network interface circuit (NIC), and the controller may be configured to send a message to a remote computing device via the NIC in response to the detected fault. The thermostat may further include a display, and the controller may be configured to cause the display to visualize a user interface, the user interface displaying at least one operational status of the thermostat based on the first measured electrical characteristic. The thermostat may further include a display, and the controller may be configured to cause the display to visualize a user interface. The user interface may be configured to receive user input and initiate a test mode based at least in part on the first power measurement circuit. The test mode may be configured to detect a voltage mismatch between the in-floor heating element and the AC power source and/or an overcurrent condition based on the in-floor heating element drawing a current from the AC power source greater than a predefined maximum current rating. The display may be configured as a touch-sensitive display.

The thermostat may further include a network interface circuit (NIC). The controller may be configured to receive data from a remote sensor via the NIC. The remote sensor may be a remote temperature sensor disposed adjacent the in-floor heating element. The controller may be configured to initiate a test mode based at least in part on the first power measurement circuit in response to receiving a request from a remote computing device via the NIC. The test mode may be configured to detect a voltage mismatch between the in-floor heating element and the AC power source and/or an overcurrent condition based on the in-floor heating element drawing a current from the AC power source greater than a predefined maximum current rating.

In accordance with another aspect, the present disclosure may feature the combination of an adapter device and a thermostat for use with at least one in-floor heating element. The adaptor device may be configured to removably couple to the thermostat and provide temporary electrical interconnection between the thermostat, the in-floor heating element, and an AC power source during installation and testing of the in-floor heating element. The adaptor and the thermostat may include any adaptor and/or thermostat described herein.

Claim 1:
A thermostat (<NUM>) for use with at least one in-floor heating element (<NUM>), the thermostat (<NUM>) comprising:
a housing (<NUM>);
a heating element control circuit (<NUM>) disposed within the housing (<NUM>), the heating element control circuit (<NUM>) to cause an in-floor heating element (<NUM>) to electrically couple to an AC power source;
memory (<NUM>) disposed within the housing (<NUM>), the memory (<NUM>) configured to store at least one predefined voltage rating representing a voltage rating for the in-floor heating element (<NUM>);
characterized in that
a first power measurement circuit disposed within the housing (<NUM>), the first power measurement circuit configured to measure a voltage of the AC power source; and
a controller (<NUM>) disposed within the housing (<NUM>), the controller (<NUM>) configured to detect a voltage rating mismatch based on a comparison of the measured voltage of the AC power source with the predefined voltage rating.