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TIIEPMOSTAT CONT~L ~F~LY
BAC~GROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates to the field of control
devices and methods for use with heating, ventilation, and air
conditioning (HVAC) units and particularly to thermo~tat-based
control devices.
PRIOR ART
The present invention relates to microcomputer-controlled
thermostat means for use in controlling the conditioning of air
in multiple zones by way of a single-zone HVAC unit.
A number of methods of controlling the conditions in a
plurality of zones from only a single zone HVAC unit are known
to the prior art. A description of the difficulties and limi-
tations associated with many of the methods attempted is dis-
closed in U.S. Patent No.- 4,530,395 (Parker, et al.) and is
relevant here. Briefly, the problems center around the means
by which a single-zone HVAC unit can be controlled from more than
one thermostat. Probably one of the best solutions to this problem
that is found in the prior art is disclosed in such patent. The
objective there was to provide control of a single zone HVAC unit
and its air distribution systems from a common set of thermostats
in two or more zones wherein each thermostat could control both
the single zone HVAC unit through a "monitor control" and its
own respective zone damper. The system disclosed in such patent
provides a "central control monitor" which receives infcrmation
from the variou~ individual ~ones and compares this information
with various preset data to then properly control the dampers
and the HVAC unit. While the system as described did meet the
objectives of multiple zone control of a single zone HVAC unit
it required the use of a dedicated microprocessor-controlled
monitor to receive data ~rom a plurality of zone thermostats.
In the present invention, similar control o~ a ~ingle zone ~IVAC
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unit for use in multiple zoneg i~ accomplished by microcomputer
controlled thermostats which can operate in either a slave or
master function thus avoiding the need for complex and dedi-
cated central control monitors. It is believed that the system
and methods in accord with this invention which allows for con-
trol of a single HVAC utili~ing master/slave thermostats in
lieu of central control units represents a substantial departure
from any prior art.
FE~TURES OF THE INVENTION
Principal features of the invention include a micro-
computer controlled thermostat wherein the microcomputer is
supplemented by (1) an electronically erasable programmable
read only memory (EEPROM) through which temperature settings
and other parameters can be stored and ~2) a read only memory
~ROM) contalning control algorithms in the form of instruction
codes and fixed data for system operation, data display, and
asynchronous communication to an external communications bus.
Programming many operations of the thermostat is accomplished
through a program switch to the microcomputer and a general
purpose interface (GPI) also having data input switches.
The thermostat also has interface circuitry to receive
inputs in the form of data and control signals and output
signals from local and remote temperature detectors and by way
of input ports.
In addition, switches allow for the enabling or disabling
of the heatlng and cooling modes of the HVAC unit.
A damper control board contains circuitry to route
; operating signals from the microcomputer to the damper motor,
the HVAC unit control relays and to an analog header for the
selective enabling of remote analog sensina devices such as
temperature and humidity detectors. The circuity in the damper
control board also enables duct temperature and damper travel
limit sensors.
In addition, the thermostat contains a real time clock
for use in programming the operation of the device during
different times-of-day and days of the week.
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SUMMARY OF ~HE INVENTION
A thermostat according to this invention is used in a
system for monitoring and controlling the condition of the air
in one or more zones when using a single zone HVAC unit. The
improved thermostat can be u~ed in a single zone mode to control
an HVAC unit or as a controlling device in a multiple zone mode
controlling other thermostats, each of which control a damper.
The thermostat employs a microprocessor-controlled circuit to
supply output signals to a damper control board having logic
circuitry to direct control signals to an HVAC unit (monitor-
stat only) or to the damper control relays and for enabling
analog sensors powered via the damper control circuitry.
The multiple zone mode involves the thermostat pro-
grammed as a "monitor-stat" to control its own damper as well
as the HVAC unit. The thermostat can also be used as a
"slave-stat" which operates a damper by use of its own pro-
gramming and in response to signals from a monitor-stat. Further,
a monitor-stat can receive data from and send data to higher
intelligence such as a computer command center. In operation, the
thermostats will be time-based with the monitor-stat including a
real time clock and transmittinq time data to each slave-stat.
In one aspect of the invention the thermostat means
operates the first control means of an HVAC unit and the control
means for one damper, and includes a first circuit means
responding to input signals for establishing operating limits
for one zone and providing a first digital word input signal
representative of such limits; second circuit means responding
to input signals indicative of the actual condition of air in
one zone for providing a second digital word output signal re-
presentative of the actual condition of air therein; third
circuit means adapted to be coupled to a peripheral circuit
for receiving data from the peripheral circuit and for pro-
viding a third digital word output signal representative of
the information contained in such data; fourth circuit means
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responding to output signals from the first, second, and third
circuit means for providing fourth digital word output signals
for operating the control means of one damper and the first
control means of the HVAC unit; programmable logic means for pro-
viding digital word input signals to the fourth circuit means for
selectively controlling the fourth circuit means; and logic means
for selectively operating one damper control means and the first
control means of the HVAC unit in response to respective fourth
di~ital word input signals from the fourth circuit means.
In other aspects the thermostat includes means for
providing information to a peripheral circuit, including any
digital word signal associated with the first, second, and third
circuit means and the programmable logic means. A first sensor
is located in a zone for providing an output signal representa-
tive of the actual temperature of the zone with the second circuit
means including means responsive to the output signal from the
first sensor for providing a second digital word output signal
representative of the actual temperature in its own zone.
The first circuit means has means responsive to input
signals for establishing the desired temperature in its own zone
and providing a first digital word output signal representative
of the desired temperature therein.
The fourth circuit means is selectively controlled by
the programmable logic means for comparing a digital word re-
presentative of the actual temperature of one zone and a digital
word representative of desired temperature in the zone for
determining the demand for heating or cooling or no demand in
the ~one.
The thermostat also includes a second sensor located in
the duct for determining the temperature therein and providing
an output signal representative of the temperature in the duct,
the second circuit responding to the output signal from the second
sensor and providing a digital word output signal representative
of the duct temperature. The duct temperature sensor is located
upstream of the damper supplying the zone.
other aspects relate to the fact that the fourth circuit
means is selectively controlled by the programmable logic means
for comparing a digital word representative of zone temperature
in its own zone and a digital word representative of duct tempera-
ture and thus determines the desired mode of operation of the
damper. The fourth circuit is also selectively controlled by
programmable logic for determining the desired mode of operation
of an HVAC unit in response to the demand for heating and cooling ;
or no demand in its own zone.
The programmable logic includes a first program such that
when duct temperature in its own duct is greater than zone
temperature a digital word output signal is provided from the
fourth circuit to the logic for operating its own damper in the
heating mode and for operating the damper in the cooling mode when
the temperature in the duct is less than zone temperature and the
HVAC unit is deactivated.
A second program is included such that when sufficient
demand for heating or cooling exists in one zone the fourth
circuit provides a first output signal to the logic for positioning
the damper in the heating or cooling mode respectively; and,
when suffficient demand for heating or cooling no longer exists
in the zone, a third output signal for deactiving the HVAC unit.
A third program i5 included such that when the HVAC unit
is deactivated, the fourth circuit provides digital word output
signals to the logic for operating its own damper in the heating
or cooling or ventilation mode in response to a comparison of duct
temperature, and desired zone temperature and actual zone tempera-
ture of the zone.
A fourth program exists such that when duct temperature
of one duct is within predetermined limits established by the
programmable logic digital word signals are provided from the
fourth circuit to the logic means for operating one damper in tne
ventilation mode when there is no demand for heating or cooling
in its own zone or a demand different from that derived from a
comparison between actual zone temperature and duct temperature
in the zone.
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An indicatin~ means provides data indicative of the
information in any digital word signal associated wi-th the
firsk, second~ and third circuit and the programmable logic.
The fourth circuit means is selectively controlled by
the programmable logic means for determining the desired mode of
operation of an HVAC unit in response to data received by the
third c~rcuit means representative of the temperature of air in
the other zones and in response to data indicative of the con-
dition of air in its own zone. The fourth circuit means is
selectively controlled by the programmable logic means in
response to data received by the third circuit means indicative
of the demand for heating or cooling or no demand from each
other zone and in response to data indicative of the demand for
heating or cooling or no demand in its zone and provides output
signals representative of the desired mode of operation of the
HVAC unit when the number of zones having demand for heating or
cooling equals or exceeds a predetermined number established by
the first circuit means.
A fifth program is provided in the logic means such that
when demand for heating or cooling exists in a number of zones
equal to or exceeding the predetermined number established by the
first circuit means, the fourth circuit means provides first
output signals to the peripheral circuit means associated with
the other zones indicative of the desired mode of the HVAC unit,
a second signal to the logic means for operatin~ the damper
associated with its own zone in the heating or cooling mode,
respectively, a third signal to the logic means for operating
the HVAC unit in the heating or cooling mode, respectively, and
and fourth outpu-t signal to the logic means for deactivating the
HVAC unit when sufficient demand for heating or cooling no longer
exists.
A sixth program is included such that when the number of
zones demand heating or cooling equals or exceeds a predeter-
mined number established by the first circuit mean~, the zone
with the greatest demand is chosen as a reference zone and the
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HV~C unit is operated by the logic means in the heating or
cooling mode, respectively, until the reference zone is sub-
stantially satisfied.
The seven-th program is included such that when the
number of zones demanding heating is equal to the number of
zones demanding cooling, with each number being greater than a
predetermined number established by the first circuit means
the fourth circuit means provides a first output signal to the
peripheral circuit means and to the logic means for operating
all dampers in a mode coincident with the heating or cooling
mode of the zone with the greatest demand, a second output
signal to the logic means for activating the HVAC unit in a
mode coincident with the demand for heating or cooling mode of
the zone with the greatest demand, and a third output signal to
the logic means for deactivating the HVAC unit when the demand
for heating or cooling has been substantially satisfied in the
zone with the greatest demand.
The eighth program is included such that when the HVAC
unit has been activated in the heating or cooling mode duct
temperature associated with its own zone and data indicative
of duct temperature in each other zone is received by the third
circuit means is compared with first predetermined limits
established by the programmable logic means and the fourth
circuit provides an output signal to the logic means for
increasing the heating or cooling supplied by the HVAC unit
when duct temperature is not within the predetermined limits.
The programmable logic means also includes a ninth
program such that when duct temperature in any zone exceeds a
second predetermined limit established by the programmable logic,
the fourth circuit means provides an output signal to the logic
means for deactivating the HVAC unit irrespective of the demand
for heating or cooling in any zone.
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A tenth program is included for operating the damper in the
heating or cooling mode when the ventilation mode is no-t applicable.
An eleventh program allows the choice of a second reference zone
when a zone develops a greater demand than the first reference zone
when the HVAC unit is being operated in a given mode.
The first circuit allows for the establishment of different
operating limits during a plurality of distinct time
periods.
The assembly is made time-based by the addition of a
real time clock and the operating limits estabished by the first
circuit means which includes the desired condition of the air in
the zone during a plurality of distinct time periods, with the
fourth circuit means responsive to signals including the data
indicative of the real time for operating the control means of
one damper and the first control means during a plurality of the
distinct time periods that are established.
The thermostat also includes means for providing informa-
tion to peripheral circuit means, the information including
real time data.
The operating limits for a zone includes the temperature
limits, and the first circuit includes means responsive to input
signals establishing the temperature desired in the zone during
a plurality of distinct time periods, and provides digital word
output signals representative of the desired temperature therein
during the time periods. Also the demand for heating or cooling
or no demand in the zone is determined during the time periods.
Similarly the desired mode of operation of the damper is
determined during a distinct time period, as well as deter-
mination of the desired mode of operation of the HVAC unit in
response to the demand for heating or cooling or no demand in
the zone during a distinct time period. When duct temperature
in the duct is greater than zone temperature the damper is
operated in the heating mode and the damper is operated in
the cooling mode when the temperature in the duct is less than
zone temperature when the IIVAC unit ls deactivated during a
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distinct time period. When sufficient demand for heating or
cooling exists in the zone during a distinct time period the
fourth circuit means provides a first output signal to the logic
means for positioning the damper in the heating or cooling mode
respectively and then a second output signal activates the HVAC
unit in the heating or cooling mode respectively; and, when
sufficient demand for heating or cooling no longer exists in the
zone, a third output signal deactivates the HVAC unit.
The program~able logic means further includes a third
program such that when the HVAC unit is deactivated, the fourth
circuit provides digital word output signals to the logic means
for operating the damper in the heating or cooling or ventila-
tion mode in response to a comparison of duct temperature of the
duct, desired zone temperature during a distinct time period and
actual zone temperature of said one zone. A fourth program is
provided such that when duct temperature of the duct is within
predetermined limits established by the programmable logic means
digital word signals are provided from the fourth circuit means
to the logic means for operating the damper in the ventilation
mode when there is no demand for heating or cooling in the zone
or a demand different from that derived from a comparison between
actual zone temperature and duct temperture in the zone.
The fourth circuit means of a thermostat is selectively
controlled by programmable logic means for determining the
desired mode of operation of an HVAC unit during a distinct time
period in response to data received by the third circuit means
representative of the temperature of air in the other zones and
in response to data indicative of the condition of air in the
zone associated with the thermostat.
The fourth circuit is selectively controlled by the
programmable logic in response to data received by the third
circuit indicative of the demand for heating or cooling or no
demand from each other zone and in response to data indicative
of the demand for heating or cooling or no demand in one zone and
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provides output signals representative of the desired mode of
operatlon of the HVAC unit during a distinct time period when the
number of zones having demand for heating or cooling equals or
exceeds a predetermined number established by the first circuit
means. Various other of the aforesaid programs, including the
fifth, sixth, seventh, eighth, ninth, tenth and eleventh,
similarly are operational during distinct time periods as would be
be apparent to those skilled in the art.
In another aspect of the invention a system for monitoring
and con-trolling the condition of the air in a single zone mode using
only a single zone HVAC unit, the thermostat has a first circuit
means responsive to input signals for establishing the operating
limits for a zone and supplying a digital word output representa-
tive of the limits including desired temperature; a second circuit
that is responsive to input signals indicative of the actual
temperature of the air in the zone and providing a digital word
output representative of the air temperature; first and second
sensors for measuring zone and duct temperature respectively and
providing signals to the second circuit means; a third circuit means
selectively controlled by programmable logic means and receiving
input signals from the first and second circuits for operating
the logic means which operates the control means of the HVAC unit.
The third circuit is controlled via several programs in
the programmable logic means for operating the HVAC unit in
response to comparisons of actual temperature, duct temperature
and desired temperature and, with real time data, the thermostat
will operate the HVAC unit via the programs in a time-based mode.
The thermostat can also operate only the damper in a slave
mode in response to signals from higher intelligence such as a
-thermostat in a multiple zone mode. The thermostat in a slave
mode has first and second circuit means for establishing desired
operating limits including desired temperature and actual tempera-
ture and first and second temperature sensors supplying zone and
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duct temperature data with a third circuit means for receiving
data from higher intelligence. A fourth circuit means is selectively
controlled by programmable logic means for operating the control
means of a damper by logic means, as before. The thermostat in the
slave mode can receive real time data from peripheral circuits for
time-based operation of several programs contained within the
programmable logic means. Improved algorithms provide improved
control over prior art deviceq.
DETAILÆD DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of this
invention are set forth with particularity in the appended
claims. The invention itself, however, both as to its
organization and method of operation, together with further
objects and advantages thereof, may best be understood by
reference to the following description taken in connection
with the accompanying drawings in which:
FIG. 1 is a front elevational view of the monitor-thermo-
stat of the control system in accord with this invention;
FIG. 2 is a pictorial diagram of the thermostat control
system in accord with this invention;
FIG. 3 is a simplified schematic diagram of the damper
control board and associated devices in accord with this
invention;
FIG. 4 iS a simplified schematic diagram of the circuitry
employed in the monitor and slave thermostats;
FIG. 5 is a detailed schematic diagram of the circuitry
employed in the thermostats;
FIG. 6 is a functional block diagram of the general
purpose inferface used in the thermostats;
FIG. 7 is a detailed schematic diagram of the circuity
of the damper control board
FIG. 8 is a simplified functional block diagram of the
central contro]. circuit of the damper control board;
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FIG. 9 is a detailed schematic diagram of the real time
clock circuitry employed in the monitor thermostat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
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Referring now to the drawing, a thermostat of the control
assembly is shown generally at 10 in FIG. 1, thermostat 10
having a removable front cover 11 and a front display panel 12
comprising a cutout section 12a for viewing a liquid crystal
display 13 and four resilient portions 12b, 12c, 12d and 12e
for the operation of four switches located below the cover 11,
and shown in FIG. 4 as switches Sl and S2 for cool setpoints
"up" and "down" respectively. In normal operation, the setpoint
for initiation of the cooling function is displayed in the
upper left hand section of display 13 and the setpoint for
initiation of the heating function is displayed in the lower
right hand section. Adjustmentofthe heating and cooling
setpoints are made by depressing switches Sl-S4 as desired.
The front cover 11 of the monitor thermostat has a cutout
section 14a for viewing the display U13 of a real time clock
14 discussed in more detail below. It is to be noted that the
slave thermostat does not includes such a cutout section 14a
in its cover since a real time clock is not neeed therein, but
the real time can be displayed on the display 13 beneath
cutout section 12a.
Referring now to FIG. 2, an overview of the operation of
the thermostat 10 in a HVAC system will be helpful in under-
standing the details hereinafter set forth. For example, four
thermostats 10 are employed in a configuration of a monitor-stat
15 and three slave-stats 30, 31, 32. The monitor-stat 15 sends
data to a damper control board 16 wherein control signals are
generated for operation of a motor 19, via motor header 13, which
controls the positioning of a damper 20. An HVAC unit 21 is
controlled via HVAC control relays 17 in response to a control
signal from da~per control board 16. Monitor-stat 15 receives
information from a real time clock 14, a zone temperature sensor
24, an outside air temperature sensor 48, a damper blad~ travel
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sensor 22, and a duct temperature sensor 23. In addition, the
monitor stat 15 transmits to and receives data from the three
slave-stats 30, 31, 32 via communicat~ons bus 49.
The HVAC unit 21 supplies heated or cooled air into main
duct 25 where it branches into four zone ducts 26, 27, 2e, 29
and then into zones 4, 1, 2 and 3 respectively via dampers
20, 39, 40, and 41 respectively, and each thermostat 10 controls
its own damper. Slave-stat 30 sends a signal to damper control
33 to operate a precision stepper motor 36 which in turn positions
damper 39. Slave-stat 30 receives data from a zone temperature
sensor 45, duct temperature sensor 42, and travel limit sensor
22a. Slave-stats 31 and 32 and their associated devices and
sensors are not directly controlled but are somewhat interrelated
with such devices employed in zone 1 with slave-stat 30 via
monitor stat 15.
The monitor-stat 15 receives data from sensors 23, 22 and
48 via a damper control board 16. As will be discussed in more
detail below, the damper control board 16 has circuitry for
enabling several analog sensors which then send their signal
data to the monitor-stat 15 or to slave-stats 30, 31, 32.
Additional sensors, while not fully described herein, may include
devices for the measurement ofj for example, air pressure, air
velocity and humidity.
Only the monitor-stat 15 includes a control function of
the HVAC unit 21. The monitor-stat 15 receives data from its
own zone and from the zones 1-3 monitored and controlled via
slave-stats 30, 31, 32 respectively. In addition, the monitor-
stat 15 has the real time clock 14 and data representative of the
time-of-day and day-of-the-week is sent to each slave-stat
30-32 in the system from the monitor stat 15, as will be more
fully explained hereinbelow.
As will be more fully explained below, a given monitor-stat
15 can itself be controlled by higher intelligence such as a com-
puter system (not shown). Communication line 49 represents the
communication network between the monitor-stat 15 and slave-
stats 30-32.
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.
Referring now to FIGS. 3, 4, schematic diagrams of the
thermostat 10 are illustrated. The thermostat electronics
comprise a conventional microcomputer Ul clocked at 6 Mhz by
way of crystal Yl and capacitors Cl and C2. Ul has interal
memory that is supplemented by programmable logic circuits
consisting of a 256-bit electronically erasable programmable
read only memory (EEPROM) U2 and read only memory (ROM) U3
which contains instruction codes and fixed data. U2 and U3
will be more fully explained hereinbelow.
General Purpose Interface (GPI) U4 provides for a number
of interface circuits including a serial asynchronous receive/
transmitted (SART), a 10-bit A/D converter, a liquid crystal
display driver, and other logic circuits which are combined in
a 68-pin integretedchip for many reasons including space, expense,
and reliability. The circuits in U4 are of conventional design
and a functional block diagram of the GPI U4 is shown in
FIG. 6.
In the preferred embodiment of the thermostat 10, GPI U4
and microcomputer Ul are connected by thirteen lines: 8 data
lines; an address latch enable (ALE); a write control (W~); a
read control (RD); a reset line; and a clock output supplying
2 Mhz to U4.
U4 receives analog temperature data from a zone tempera-
ture detector or sensor such as 24. Each of sensors 24, 45, 46,
47, which can be located at the thermostat 10 or at a remote
location in the zone, are a current source with a 1.0 ua/K output
which is received by the A/D converter in U4. The data is then
sent to Ul in digital form. Each of the sensors 24, 45, 46, 47
is enabled via a respective signal from its Ul in response to
control algorithms in U3 and is sent to U4 at input "CHO"
(channel 0).
As discussed above the thermostats lS and 30-32 control
respective damper 20, 39, 40, 41 by way of a precision stepper
motor 19 and 36-3a and thermostat 15 activates and deactivates
an HVAC 21 via control relays 17. ~1 transmits an 8-bit command
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word into U4 where it is Eramed to an ll-bit word and tranYmitted
to the damper control circuitry 16 and 33 by synchronous trans-
mission. The transmission is clocked by way of division of the
2 Mhz clock signal received from Vl down to 9600 Hz. As
explained below, the damper command word contains information
which can be used to select analog signals located on the damper
control board 16 or 33 for A/D conversion in U4 and also for
control of a HVAC unit 23.
The monitor-stat 15 has provision for physically mounting
a real time clock 14 in the housing 11. If this option is desired,
a housing cover 12 will have the cutout portion 14a for viewing
the integral display face of the clock 14.
The damper control board 16 is illustrated in FIGS. 3,7 and 8.
U7 receives a synchronizing signal ~DSYNC) and the damper control
word (DPRDAT) from U4 via T8, T9 and TIl. An input shift
register 55 directs the word to data path select logic 56 where
it is directed to HVAC unit control 17; motor control TS2 or
sensor select enabling circuitry TSl. The sensor select circuitry
57 is used to enable one of several analog sensors, such as
outside air temperature detector 48 and others, such as, air
pressureandhumidity (if available). The sensor select 57
is not needed to enable duct temperature sensor 23 and damper
travel limit sensors 22, 22a, 22b, 22c. The travel limit
sensor 22 is a digital Hall effect device that nrovicles an output
when the damper blade 19b i9 at its maximum travel limit and another
output when the blade is at any other position. Duct temperature
and travel limit data are constantly monitored by each thermo-
stat. The sensor select logic 57 is used to select which o~
the optional analog detectors, such as outside air temperature
sensor 48, will be enabled. Sensor select 57 is responsive
to data contained in the 8-bit damper command word. The selection
between damper motor control logic 58 and HVAC relay control 17
is also based upon data in the damper command word. For
reliabillty, the circuitry also has various watchdog and hardware
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redundance functions relating to hardware functioning and input
clock signal integrity. Data verification logic 62 works in
conjunction with latches 57, 60, 61 to provide a check of
hardware redundancy. Input clock timeout 62, input data timeout
63 and reset logic 64 circuits are used with signal monitoring
and reset functions.
Damper control board 16 includes opto-isolation U8 for
the motor control relays to isolate inductive transients in
the circuitry by isolating control power from operating ~ower.
The motor header TS2 is fed via hex inverter U9. TS2 and U9
are combined in TS2A for simplicity of illustration in FIG. 3.
U7 is clocked at 48 Khz from oscillator A3. The two other
amplifiers _ and A2 in U7a are part of the U7 monitoring_
system, including power supply availa~ility. Terminal "G" on
TI2 provides analog sensor data to the U4 ~/D converter. As is
understood in the art, electrical circuitry, associated with
relays must be designed to eliminate noise and signal transients
associated with relay operation such as inductive kick, contact
bounce, and the like. In addition, AC signal noise must be
eliminated from analog sensor signal lines. Accordingly,
isolation resistors and capacitors are used throuahout the
circuitry, as is the case with most electronic design. Also,
in the preferred embodiment of the present invention, TS3 has
terminals for supplying power of additional circuits. The design
approach is to supply line power to the damper control board 16
which in turn supplies the various controls used in the system
via relay boards that are tailored for a sepcfic application
te.g. single zone; multiple zone, etc.).
The real time clock 14 is illustrated in FIG. 9. The
real time clock circuitry Ull contains an input from a
crystal oscillator Yl (see FIG 53) and the necessary counters,
latches and so forth. Clock controller UlD reads data ~rom
Ull in response to time data request signals from microcumputer
Ul. The data is framed from ~-bit to 10-bit words for trans-
mission to U . U10 also supplies data continuously to display
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driver/decoder U12 where it i9 directed to liquid crystal
display U13 for visual readout. Switches S10 aand Sll are
used for setting the clock controller U10 to a reference time
during start-up of the system. In the preferred embodiment
of the invention, capacitor C48 is a large (.lf) capacitance
to supply Ull during power failures. "Clock Reset" is used in
the time-of-day (12-hour AM/PM) and day of the week reset
functions via a signal from Ul.
The present invention employs the concept of firmware
engineering in the design of the thermostat 10. The basic
approach is to build a single thermostat 10 that can be used
with other devices in a master-slave relationship. One
thermostat 10 is chosen as a master or "monitor-stat" 15 and
the others are "slave-stats" 30-32. The thermostat 10 has
control algorithms or programs in U3 for purposes of, among
other things, transmitting and receiving data from other
thermostats 10 or devices. In addition, and quite importantly,
this design allows a monitor-stat 15 to operate a single zone
HVAC unit 21 in a single zone mode of operation where zoning
is not required and to control a damper 20 based upon informa-
tion associated with its own zone ln a multiple zone system.
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A description of the progra~ning and operation of the
thermostat L0 will illustrate the unique features of the
present invention.
PROGRAMMING T~E THERMOSTAT
1. Zone Number
In order for a monitor-stat 15 to communicate with one or
more thermostats 10 functioning in a slave capacity as slave-stats
32, it i5 necessary to establish the identity of any given thermo-
stat 10 or device so that data can be associated with a given
device.
The zone number of the thermostat 10 is established by way
of S1-54 and S5. S5 is a 16-position rotary switch which sup
plies a 4-bit binary coded decimal word to the input bus of U~.
The use of a BCD word and switches Sl-S4 allows for the creation
of an 8-bit input word. The normal position of S5 is "O". Wi-th
S5 in position "1", the zone number will be displayed on display
13. _ can be used to raise the number, S2 can be used to lower
the number. The monitor-stat 15 in any given application is
always given the highest number as a matter of firmware design.
The zone number is placed in EEPROM U2 via Ul.
2. Single Zone or Multiple Zone Mode
The thermostat 10 can be used for a single zone thermostat
or it can be used as the monitor-stat 15 in a multiple zone mode
that employs a number of slave-stats 30-32. When S5 is in position
"1" the display 13 will be illuminated with the word "ON" or "OFF".
When the display 13 shows "OFF" the thermostat 15 is in the single
zone mode and does not require data inputs from other devices in
order to control the glven zone. When the display 13 indicates
"ON" the thermostat 10 is enabled for use as the monitor-stat 15
in a multiple æone system. Either of switches S3 and S4 can be
used to toggle the function on or off. When the multiple zone
mode is enabled ("ON"), firmware via U3 is used to control the
system based upon data received from other sources. In either ca~e
the monitor-stat 15 is responsive to its own data bein~ supplied by
its own sensors.
-18-
~2~35~2
3. Program Period~
A monitor-stat 15 has the capabllity of receiving data
from a real time clock I4 by w~y of pins on Ul. As far as the
system operation is concerned, U3 instruction codes divide time
into two categories. First is Period I and Period II which
represent days of the week. With S5 in position "2", switches
Sl and S2 can be used to raise or lower the number associated
with the beginning day of Period I. Each day of the week has been
assigned a number beginning with Monday = 1 and ending with
Sunday = 7. The display 13, with S5 in "2", will show the be-
ginning and ending day of Period I. S3 and S4 are used to set the
ending day. Thùs, a "2" and "6" displayed indicates that Period I
is Tuesday through Saturday. The instruction codes automatically
establish Period II as the remainder o~ the week (i.e., Sunday
through ~onday). A slave-stat 30-32 receives real time data fro~ the moni-tor-stat
15. A slave-stat 30-32 also has time period programming identical to ~onitor-stat 1~.
The second category of time is the time of the day. ThiS
feature employs the use of RAM in Ul and will be discussed here-
inbelow.
4. Celcius/Fahrenheit Data Display
A relatively straightforward algorithm is used to allow
the display to present data in either C or F. The display 13
will alternate between "F" or "C" when Sl or S2 is depressed with
S5 in position "3".
5. Set~up/Set-back Setpoints
In many applications it is desirable to establish heating
and cooling setpoints for occupied conditions and have diEferent
setpoints for times when the ~one is not occupied. Set S5 to
position "4". The cooling set-up setpoint will be displayed when
Sl is depressed to raise the cooling setpoint to 1F greater than
the 66-80F range set in U3. Thus, raising the cooling setpoint
to 81F with S5 in "4" will display the set-up setpoint which can
then be adjusted to any point between 8l-96oF. Simi}arly, ad-
justing the heating setpoint to below 66F will display the heating
set-back setpoint which can be adjusted using S3 and S4 to between
50-65 F. The programmed set-up/set-back setpolnts are usecl ln
conjunction with ~irmware and are neces~arily time depend~nl: as will
b~ described hereinbelow.
--19--
5~
6. Zone Temperature Calibration
With switch S5 in position "5", switches Sl and S2 can
be used to adjust the calibration of the A/D circuitry which
receives signals from zone sensors 24, 45-47. The calibration
is accomplished using a reference thermometer. The A/D circuit
supplies a lO-bit word for the temperature (2 bits for the
most significant bit, Mss~ and 8 bits for the least significant
bit, LSB). A 2-bit calibration word, 1 bit for MS~, 1 bit for
LSB, is entered in the U2 EEPRO~ for use in modifying the tem-
perature word so that the temperature reading on the display
13 is the same as that read on a reference therrnometer. This
data is provided to U4. A calibration word placed in U2 will
modify the A/D output signal representative of temperature so
that the exact temperature will be used in the circuitry. The
calibration word is modified by Sl and S2 until the temperature
displayed on display 13 is the same as that on the reference
thermometer..
7. Duct Temperature Calibration
The system employs duct temperature sensors 23, 42-44
upstream of the dampers 21 and 37, respectively. With SS in
position "6", _ and S2 can be used to calibrate duct temperature
in the same manner as utilized in æone temperature calibration.
The technique utilized in the calibration of zone and
duct temperature can be used with any analog sensor supplying
an input to U4 with the addition of appropriate programming of
U2 calibration words and instructions.
-20-
3l~93~
8. Ventilation and Maximum Damper Positions
The monitor-stat 15 receives data by way of driver U5 and
GPI U4 SART. AS will be explained in more detail below, the
monitor-stat 15 determines whether the system (the ~VAC unit 21and
the dampers 20, 29~41) should be in a heating or cooling mode by
analyzing the demand for heating/cooling in each zone. This de-
mand is defined as the difference between the zone setpoints and
actual zone temperature. If there is not sufficient demand for
heating or cooling the dampers 20,39-41 are placed in "ventilation"
mode. Set S5 to "7" and the damper ventilation mode position data
will be displayed on display 13. Switches S3 and S4 are then used
to set the damper 21, 37 from 0~ open (Display = "0") to 50% open
(Display = "7").
Also in position "7", the maximum open position of the
da~per 2a, 39-41 can be adjusted using switches Sl and S2 between
100~ open (Display = "15") to 50~ open (Display = "8").
-21-
3~;5:~
9 Setpoint Lock/Override
A unique feature of the present invention is the ability
to lock the wne temperature setpoints via the system firmware.
With S5 in "8", either Sl or S2 can be depressed to alternate the
words "ON" or "OFF" on display 1~. When "ON'' is displayed at the
monitor-stat 15, all zone temperature setpoints on slave-stats 30-32
are locked as set. "OFF" allows zone temperature setpoints to be
adjusted at each of the slave-~tats 30-32.
q~e slave-stat 30-32 also has provislon for override of the
locking feature of monitor-stat 15. By placing the slave-stat
switch S5 in position "8", depressing Sl and S2 will cause the
words "ON" or "OFF" to be alternately displayed at the sLave-stat
30-32 and when "OM" appears, thç lock feature of monitor-stat 15 is
overridden at the particular slave-stat 3()-32.
10. Local Setback Control and Time-Of-Day Program
Set swltch S5 to position "9". The pressing of either Sl
or S2 will alternate the words ~'ON" and "OFF" on display 13. When
"ON" is displayed, a slave-stat 30-32`will operate on its own pro-
grammed set-back times. When "OFF" is displayed, a slave-stat 30-32
will operate on the setback times of the monitor-stat 15.
For the monitor-stat 15 the use of "ON" results in the
monitor-stat 15 following its own set-back times as might be
the case when the monitor-stat 15 is in a single zone control
mode. When "OFF" appears, the monitor-stat 15 will follow time
commands from another device such as a computer command center,
or other device such as another monitor-stat L5.
With switch S5 in 10- the set-back times can be progra~med.
Program switch S6 is depressed and fan switch S7 can be placed
in "auto" to represent period I (as programmed earlier, see 3.
Program Periods, above). Now, if both S3 and S4 are depressed
simultaneously, the last program (stored in Ul) will be erased.
Switch Sl is used to advance time. "ON" will be displayed in the
__
upper left hand corner of display 13. "A~" will be displayed in
the lower right hand corner. Time is advanced, hourly, unti:l the
desired hour is displayed, Either switch S3 or S4 can be de-
pressed to indicate "OFF~. Sl can then be depressed to dlsplay
-22-
~935S2
the tlme of day that setback should occur. The thermostat 10
is now programmed to follow the cooling/heating setpoints be-
tween the "ON" and "OFF" times and revert to the cooling set-up/
heating set-back setpoints as previously established at the "OFF"
tlme, i.e., when the comfort or occupled function is "OFF" the
set-back feature is operative.
If switch S3 is now depressed, the word "ON" will appear
and a second set-back time period can be programmed as before.
Depress program switch S6 and the Period I setback times are
entered.
To program for Period II, set S7 to "ON" and depress S6.
Period II set-back times can now be programmed as were Period I
times.
Ul in the monitor-stat 15 can receive real time ~a~ via pin~ P15 and P16.
In addition, the use of control algorithms and switches S1-S4
and S5, S7 allows for the creation of distinct time periods:
(l) Period I and Period II having to do with the days of the
week; and (2) at least two distinct time periods of a given day.
With the use of the real time data, the desired temperature be-
comes time dependent as it is now associated with a given time
period. A slave-stat 30-32 receives real ti~e data via o~m~nications bus 49.
ll. Information Display
With S5 in position "A", Sl and S2 can toggle "O~" or "OFF"
the Information Display option. If the display 13 is "ON" then,
when both Sl and S~ or S3 and ~4 are simultaneously depressed
with S5 ln "0" (Normal), the room temperature will be displayed
tas usual) followed by time-of-day (if available), duct temperature
and damper position (desired/a~tual), in that order. In addition,
air pressure and air velocity in the ducts 26,27,28,29 can be displayed
if the appropriate sensors are installed.
12. High/low Temperature Limits
The rotary switch S5 i5 placed in position "B". Depressing
either Sl or S2 will alternate the words "GE" ~for Gas~Electric)
or "HP" (for Heat Pump) on display 13. The monitor-stat 15 i9
programmed to automatically shut down the first and/or seaond
stages of heating or cooling if certain temperature limits are
-23-
1~35S~
excee~ed. The trip pointg are different for Gas/Electric or
Heat Pump applications. Selection of "GE" or "~P" depends
upon the type of HVAC unit 21 used.
Either switcheR _ and S4 can be used to alternate "ON"
or "OFF" to allow the High/Low temperature trip points to be
turned on or off. The monitor-stat 15 constantly receives,
preferably every 20 seconds, duct temperature data from all
zones via the slave-stats 30-32. A single High or Low duct tem-
perature reading is sufficient to activate the setpoint trip.
13. Outside Air Temperature
In systems using heat pumps it is desirable to limit
set back when outside temperature gets too cold because heat
pumps become inefficient at low temperatures. Electric resis-
tance heating can be used but is expensive. Accordingly, it
might be advisable to override set-back when recovery from the
set-back temperature requires electric resistance heating be-
cause the heat pump is inefficient at the given air temperatures.
In the preferred embodiment of the invention the monitor-
stat 15 will override set-back when an optional outside temperature
sensor 48 indicates 30F or lower.
The enabling or disabling of the outside air temperature
sensor function is accomplished by placing S5 in position "C"
and pressing either S3 or S4 to toggle "ON" or "OFF" on the dis-
play 13.
14. System Demand
The monitor-stat 15 receives information from the slave-
stats 30-32 every 20 seconds. Data received includes the heating/
cooling setpoints and zone temperature. Sufficient zone ~emand to
activate the HVAC unit 21 is defined as any zone having a tempera-
ture more than 1.5F from the setpoint (in the appropriate direc-
tion). The monitor-stat lS will place the system in a heating or
cooling mode depending upon the number of æones indicating suffi-
cient zone demand. With S5 in position "C" the system demand
number i9 displayed. Switches Sl and S2 can be uged to adjust
between l and ~ zone demands needed to establish gystem mode.
-24-
~;~93SS2
15. Communications Check
_ _
With S5 in position "D", the depressing of Sl or S2
will initiate a communication check between each slave-stat
30-32 an~ thel~nitor-Stat 15. The zone number of each slave-
stat 30-3' will be momentarily displayed along with a data word
indicating whether theslave-stat 30-32 is a "cooling caller";
"heating caller"; a "cooling" or "heating" reference; or has
a specific demand. The system status will be explained below
in the System operation.
16. Supplementary Heat
For a number of reasons usually dealing with the speciEic
building construction and location, supplementary heat such as
baseboard heaters might be desirable. ~ith switch S5 in position
"E", switches _ or S2 can ~e used to toggle the option "ON" or
"OFF". Supplementary heat works in conjunction with an outside
temperature sensor 49 in a special mode of operation that need
not be further discussed herein.
17. Time Guard Override
This feature involves S5 in position "F" and the toggle
"ON" or "OFF" of a function to override a built-in time delay
associated with cycling of the HVAC unit 21.
As can be understood from the above descriptions of the
programming of the thermostat 10 and the electronic circuits
involved, the approach that is used in design of the thermostat
l0 allows for maximum capability of the system in which it is
used. Further, the thermostat 10 needs only switch connectlons
S8 and S9 to enable heating and cooling control in the master
or monitor-stat l5 function. The programmable logic of U2 and
U3 supplies the fixed data and instruction for operation of Ul
as a monitor-stat 15 or a slave-stat 30-32~ith the associated
programmed operations.
The monitor-stat lS controls both a damper 2~ for its
zone and the HVAC unit 2L supplying the system. Ul generates
an 8-bit damper command word which i9 modified or synchronous
transmission by GPI U4. In the preferred embodiment of the in-
vention, the most siqnificant bit ~MS~) of the damper command
1~35~;~
word is different for (l) control of damper 21 or (2) control
of HVAC unit 21. Switches S8 and S9 provide data inputs into Ul
to assist in the creation of a MSs of the damper command word
that is recognized by control circuitry 16 ~s that ass~cia~ed with
the damper 20 or the HVAC unit 21. Referring now to the de-
tailed schematic o~ FlG. S the operation of the thermostat 10
will be described more fully.
system Operation
The heating and cooling setpoints are entered into the
memory of Ul via switches Sl-S4 and S5 and GPI U4 as discussed
above. Actual temperature in the zone associated with the ther-
mostat 10 is derived from sensors 24, 45-4? and can be read by
manually simultaneously depressing Sl-S2 or S3-S4. Instructions
derived from _ will cause data representative of the actual and
desired temperatures to read into Ul. A comparison of the two
temperatures results in the creation of a signal representative
of the demand for heating or cooling or no demand in the zone.
Instructions in U3 in the monitor-stat 15 predetermines that a
1.5F or greater di~ference between actual and desired temperature
is necessary before there is sufficient demand to generate the
signals for operation of the system in the heating or cooling
mode by activating the HVAC unit21., If there is sufficient
demand, Ul will generate an 8-bit damper command word which is
sent to U4 via the 8 data bus lines. The 8-bit word is framed
to 11 bits for synchronized transmission to the damper control
circui~y 16. The~SB of the word is recognized by the control
circuitry in damper control board 16, 33-35 as heing for oper~tion of
the damper 20, J~-4l. After a time interval of, for example,
30 seconds which i~ established by code in U3, the damper command
word is modified to have a MSB that is recognized by the control
circuitry as being for operation of the HVAC unit 21. As before,
the damper command word is transmitted to the damper control cir-
cui~y 1~ ic~lc~n operate the HVAC unit control circuit 17. As
mentioned above, U3 code include~ control algorithms for operating
either a Gas/Electric or heat pump as programmed. This feature
-26-
~355;Z~
set~ temperature limits for safe operation of the system and
proper levels of additional heating or cooling as appropriate.
If the HVAC unit is not energized, ul iA the thermostat
lO compares actual temperature in the zone with duct temperature.
The du~t temperature sensors 23, 42-44 are located adjacent the
inlet of the dampers 20, 39-41 supplying air to a given zone. In
the preferred embodiment of the invention, the duct temperature
sensors 23, 42-44 send a signal to circuitry associated with damper
control boards 16, 33-35. This d~ta is received by ~4 on Channel 1
(CH 1) along with other in~ormation that is deve-oped remotely. This
data undergoes A/D conversion as does the zone temperature from
sensors 24, 45-47.
If the duct temperature is lower than actual zone temperature
the thermostat lO will operate the associated dampers 20, 39-41 in
the cooling mode. If the duct temperature is above the actual
temperature, the associated dampers 20, 39-41 are operated in a
heating mode. That is to say, the dampers 20, 39-41 are operated
as though the ~VAC unit 21 was supplying the hotter or cooler air.
Consider the case where actual temperature is below the heating
setpoint with duct temperature also below the actual temperature:
A. the particular zone has demand for heating but is in the
cooling mode; B. accordingly, the dampers 20, 3g-41 are closed;
C. however, i the duct temperature was above the actual tempera-
ture, i.e., heating mode, the damper 20, 39-41 wlll open proportion-
ally to the level of demand as computed by a comparison of actual
zone vs. setpoint temperatures.
If the demand for heating or cooling is l.S~F or greater,
the monitor-stat 15 will activate the ~VAC unit 21 as desired.
A damper command word is generated, for example, cooling, and the
dampers 20, 39-41 are placed in the cooling mode regardless of the
duct temperature comparison discussed above. If the zone has an
actual temperature below the heating setpoint, the dampers 20, 39-41
will be closed in anticipation of activation of the }~VAC unit 21
in the cool.ing mode. If the actual temperature is above the
cooling setpoint, the dampers 20, 39-41 will be positioned open.
-27-
33S~;~
Ul in monitor-stat 15 now generates an output damper command
word for activating the HVAC unit 2I in the cooling mode.
If the monitor-stat 15 is operating in the multlple
~one mode, instr~lction codes in U3 will not generate the
darnper command words for operating the dampers 20,39-41 ~ HVAC
unit 21 unless the number of zones with 1.5F or more demand
in a given mode is equal to or greater than the system demand
number that has been selected as discussed above.
The monitor-stat 15 also uses duct temperature directly
to determine if additional stages of heating or cooling are re-
quired in a given mode. For example, if duct temperature is
not below 55F when the system is in a cooling mode, the damper
command word will contain information that will cause HVAC con-
trol circuitry 17 to energize an additional stage of cooling.
The additional heating or cooling functlons derive from codes in
U3. Finally, duct temperature is used directly for high/low
temperature trips of the HVAC unit 21 for safe system operation.
1. Communications
In the preferred embodiment of the present invention, the
SART in GPI U4 is used for communicàtion with peripheral circuits.
Input data from the SART and data switches Sl-S4 and S5 is placed
in registers in U4 which can be read by Ul. U4 also contains an
8-bit address bus for accessing microcode in U3.
Collision avoidance for the communications network 31 is
accomplished by load resister R6 which monitors the current re-
quired by line driver U5. Q3 is turned on by line current through
R6 and an Interrupt (INT) signal is placed on pin 6 of Ul. Capac-
itors _ and C6 filter noise which might otherwise result in false
collision detection indications.
2. Watchdog Functions
U4 also performs watchdog functions to insure proper opera-
tion of the thermostat 10. A voltage divider of R15 and R:L6 ap-
plies a signal to pin 57 of U4. When and if the voltage is too
low, Ul i9 disabled by a signal on the reset line between Ul and
U4. U4 also receives timing data from Ul. If the proper timing
data is not received, Ul will be disabled via t~le reset line.
-28-
3 Digital Functions
An lmportant feature of the thermostat 10 lS the exclusive
use of all data in digital form. For example, the heating and
cooling setpoints are entered into U4 by switche~ Sl-S4 and S5.
The SART in U4 also places incoming information on the same
registers used for setpoint input. As mentioned above, firmware
in conjunctlon with the programming allows for setpoint lock from
the monitor-stat 15 to a slave. Further, there is provision at
the sl~ve-s~t~30-32 for override of the remote setpoint lock
feature. This is made possible by the use of digital data format~
Also, analog temperature data is converted into digital
form in the A/D converter in U4. The digital form allows for
calibration of the data by way of the software because each tem-
perature interval is a binary word. A calibration binary word
can be placed in U2 for calibration using S5 in position "5" or "6".
Similarly, other remote data can be accessed by the thermostat lO.
Data in analog form can be enabled via the instruction codes and
converted to digital form in U4. For example, in the preferred
embodiment of the thermostat lQ, various analog data is accessed
by way of the damper controlcircuitry 16, 33-35. By modification of
the damper command word, different remote data can be enabled and
received at C~ 1 of U4. Because the enabling was done via Ul command
word generation, the incoming data is easily identified and properly
processed.
The use of digital data allows for the transmisslon of any
information at a thermostat 10 to any higher intelligence as well
as the reception of data for processing and control. Also, the
thermostat 10 has internal diagnostics and system failures can be
identified by data presented on display 13. For example, failures
having to do with the setback setpoints is identified as "SF 2".
A hardware failure might be "HF 16": zone temperature sensor out
of range.
Finally, real time data can be received by monitor-stat 15
in digital form. This data can be transmitted by way of U4 SART
for supplying data representative of time to other peripheral
circuits such as a sla~e-s~at30-32~ Thig function is used in the
-29-
~LZ~3S52
set-up/set-back setpoint and time periods as discussed above.
Also, because of the digital nature o all data, the ti~e in-
puts may be simply "ON" or "OFF" signal~ derived from an electro-
mechanical timer using simple relay contacts that are either
opened or closed at a given time.
Liquid crystal display 13 is a conventional tri-plexed
display driven by U4 and used for local indicating mean~ for
data display.
If the monitor-stat 15 has been programmed for multiple
zone use, the level of demand from each zone is read by re-
ceiving the actual deviation of room temperature from setpoint
temperature. In the preferred embodiment of the invention, all
thermostats 10 are specifically designed to compute the level of
demand rather than simply exchange a "YES" or "NO" signal. This
feature allows the monitor-stat 15 to compare the level of de-
mand in each zone and select the zone with the greatest demand
as the reference zone. Other thermostats 10 are heating
callers" or "cooling callers" if demand for heating or coollng
exists in the given zone. The thermostat 10 will operate the
HVAC unit in the appropriate mode until the reference is within
.5F of the setpoint. For example, the system demand number may
be "3" thus requiring 3 zones to have a similar demand for heating
or cooling before the heating or cooling mode is selected but the
mode once selected will remain in effect until the reference zone
is satisfied. A new reference zone will be chosen if a zone develops a greater
demand than the first reference during operation in a given mode.
Once the reference zone is within .5F of the setpoint, the
monitor stat 15 will generate the appropriate damper command word
to deactivate the HVAC unit 21 via HVAC control circuit 17. Assume
that cooling was being supplied and the HVAC unit 21 is deactivated.
The duct temperature at each zone will be below actual temperature.
Thus, the comparison between duct and zone temperature will result
in the monitor-stat 15 placing its damper 2a in the cooling mode.
As a matter of design, each slave-stat 30-32 will alsoposition its
damper 39-~1 in the cooling mode.
With the HVAC unit 21 deactivated, duct temperature will
gradually increase, I~ duct temperature riseg above zone t:emperature,
.
-30~
1~3~5~:
the thermo~tat 10 will operate i~s damper in the heating mode.
As a matter of de~ign, the heating and cooling setpoints are
established by U3 to be within 65-80F. ïf duct temperature is
within the range 65-80F and there is no demand or demand dif-
ferent from the mode created by the duct/actual comparison, the
da~ers 20, 39~41 placed in the ventilation mocle. In the above
example, where cooling was being supplied, the dampers 20, 39-41
will remain in the cooling mode because actual temperature will
probably be above the cooling setpoint due to the am~ient heat
sources that caused temperature to increase in the first place.
In the preferred embodiment of the present invention, power
is directed to a thermostat 10 from its respective damper board 16,
33-35 via a 12- conductor rib~on having terminals Tl-T12 for power
input and communications therebetween. Voltage regulator U6 is a
conventional device for supplying a regulated ~5 vdc to various
circuit points. Another voltage of +9.3 vdc is also supplied from
damper boards 16, 33-35. As is understood in the art, the completed
circuit illustrated in FIG. S comprises filter capacitors and
resistors for signal isolation and noise suppression and the like.
Terminals Tll and T12 are the connection points used if zone tem-
perature sensors 24, 45-47 are located in the zone instead of physi-
cally connected to the housing 11 of the thermostat 10. Transis-
tors Ql, Q2 and assoclated components are used to enable the sen-
sors 24, 45-47
In accordance with the present invention the thermostat 10
can be used in the capacity of a monitor-stat 15 which essentially
controls the system with a number of slave-stats 30-32 or as a
monitor-stat 15 which is controlled by higher intelligence. The
monitor-stat 15 controls its own zone conditions and the conditions
in each other ~one is controlled via a slave-stat 30-32. Each ther-
mostat 10 operates dampers 20, 39-41 ~n the ducts 26-29 that directs
air into the zone. The monitor-stat lS can also control an HVAC
unit 21. Importantly, the monitor-stat 15 can operate in a single
zone mode without a damper 20 by simply controlling the operation
of an IIVAC unit 21.
The major di~tinction~ between a thermostat 10 used as a
monitor-stat lS and ag a slave-stat 30-32 are (1) the monitor-stat lS
--31--
~93S5Z
has the in9truction code3 and data in U3 for operation as a
master controlling device; (2) the monito~-stat 15 has pro-
visions for a real time clock input data and the programming
to make use of such data; (3) the monitor-stat 15 ha3 heat
switch S8 and cool switch S9 for operation of an HVAC unit 21;
and (4) the monitor stat 15 has additional programming capability
due to codes stored in U3. These fea~ures allow the monitor-stat
15 to receive, process and transmit information to one or more
slave-stats 30-32. In addition, the monitor-stat 15 can receive and
transmit information to higher intelligence. Thus, a plurality
of monitor-stats 15 each associated with its own EVAC unit 21
and a ~roup ofslave-stats 30-32 may be under control of a central
computer system. Furthermore, because a monitor-stat 15 can op-
erate in a single zone mode as well as in multi-~one mode, there
i9 virtually unlimited ~lexibility in overall system design for
use of such thermostat 10.
The features of the thermostat 10 used respectively as a
monitor-stat 15 and a slave-sta~ 30-32 are as follows:
Each thermostat 10 is programmed for zone number; pro-
gramming periods; C or F display; set-up/set-back setpoints;
calibration of zone temperature sensor; calibration of duct
temperature sensor; and damper travel limits/ventilation mode
travel limits. The monitor-stat 15 can be programmed to lock
slave-stat 30-32 setpoints; the slave~stat 30-32 can be programmed to
override this lock feature. The sIave-stat 30~32 can be programmed
to follow the set~back times of another device or to follow set-
back times programmed at the slave-stat 30-32. The monitor-stat 15
may be programmed to follow its own set-back times or to follow
those of a higher intelligence. The monitor-stat 15 alone hac~
the following programmable features: (1) the high/low tempera-
ture limits set in U3 are made operational by establishing that
the EVAC unit 21 in use is Gas/Electric or ~eat Pump; (2) the
system demand number; (3) the communication check ~eature; and
~4) the supplemental heat/tima guard override features. The
monitor-stat 15 alone also has the capability to reaeive real
time data directly and such in~ormation can be tran~mitted to all
slave-st~t 30-32 via the SART in the monitor-stat 15.
-32-
- ~LZ~3355Z
The general design of the thermo~tat 10 employs digita
word~ and programming to accomplish the various tasks. The
characterization of the thermostat 10 as a moni~or-stat 15 or
slave-gtat 3~ i5 done by way of the instruction codes in U3
and, in the case of the monitor-~tat 15, the addition of "heat"
switch S8 and "cool" switch S9 to Ul and the provision for a
real time clock input signal to Ul from clock ].4.
The system employs a first circuit subsystem comprising
switches Sl-S4 and S5 which provide ~-bit digital words into U4
for establishing the desired operating limits, such as tempera-
ture setpoints. In addition, switches Sl-54 and S5 are used in
the programming of the thermostat 10 by providing digital words
to EEPROM U2 and accessing digital words contained in U2 for use
in sensor calibration; for establishing the minimum and maximum
damper position in a given mode (ventilation, heating, cooling);
and for establishing the applicability of the high and low tem-
perature trips for given type of HVAC unit 21 (Gas/Electric or
Heat Pump).
A second circuit subsystem receives sensor data indicative
of the actual condition of the air in a zone (temperature, pressure
velocity, etc.) and such data is received directly by U4 in the
case of actual temperature and indirectly from the damper control
circuitry 16, 33-35 with regard to duct temperature, and, if needed,
air pressure, velocity, humidity, and outside air temperature. The
A/D converter in U4 will provide a 10-bit digital word output that
is representative of the analog data received from such sensor.
A third circuit subsystem represented by microcomputer Ul,
receives digital word inputs from U~ and U4 that represent pro-
grammed data and actual data with regard to the operating condi-
tions of a given zone. Ul will provide a digital word output in
response to data received from U2, U4 and its own RAM for operating
the dampers 20,39~41 and, in the case of the monitor-stat 15, for
operating the HVAC unit 21.
A fourth circuit subsystem represented by the programmable
logic of U3 and U2 provides digital word data to Ul for controlling
the damp~s 20,39-41 and/or the ~VAC unit 21.
In accord with this invention, there are some overlaps
of the ~irst, second, third and ~ourth circuit subsy~tems for
reasons of simplicity, cost and reliability. For example, the
RAM in Ul is used in programming the time~of-day as~ociated
with set-up/set-back setpoints in conjunction with S6 as a
matter of convenience while EEPROM U2 is used for (1) device
address/zone number; (2) standard setpoints; (3) setback set-
points; (4) open/close damper travel limits; ~5) setback
programs, periods I, II; (6) zone temperature calibration
words; ~7) various options such as ~a) lock/override; (b) HVAC
type; (c) temperature readout selection in F or C; and (d)
local or remote setback control. This particular circuit com-
bination allows the user to change the time-of-day associated
with setback without accessing U2 via S5 and thus inadvertently
altering the programs established by the installer of the ther-
mostat 10. In the preferred embodiment of the invention, a
physica~ barrier is placed over S5 which should be removed only
by an installation technician to minimize such alterations.
In the preferred embodiment of the present invention,
second temperature sensors23r42-44 are used to measure duct tem-
perature. The sensors are placed upstream of the dampers 20, 39-41
supplying a given zone. The analog signal is sent from the
damper control boards16, 33-35 to the A/D converter in U4 via CH 1.
U4 provides a digital word output representative of the duct tem-
perature. U3 contains in~tructions which cause Ul to compare the
digital word received from U4 representative of actual temperature
with the digital word, also from U4, representative of duct tem
perature. The result of the comparison in Ul is then used, in
conjunction with instructions in U3 regarding mode, to determine
the desired mode of operation of the dampers 20,39-41, i.e., heating
or cooling. ~he instructions contained in U3 are written to allow
time, about 30 seconds, for operation of dampers 20, 39-41 prior to
activation of a HVAC unit 21 In addition, the dampers 20, 39-41
are placed in a mode coinaident with that o f the HVAC unit 21-
Accordingly, digital words indicative of the status of the HVAC
unit 21 as well as the degired status of the unit 21 ~i.e., desired
mode) are generated and supplied to a slave-stat 30-32via the SART
-34-
93~i52
in U4. In the case of a monitor-stat 15, Ul, of course, gen-
erateq the desired mode digital words itself by a comparison
of duct and actual temperature of it~ own zone for its own use
in addition to transmitting the digital words to various slave-
stats 30-32 via ~he U4 SAR~. The monitor-stat 15 may cause the ener-
gization of additional stages of heating or cooling if duct tem-
perature does not reach a predetermined point within a given
time interval of about 5 minutes after the HVAC unit 21 is
activated in a given mode. The
predetermined duct temperature limits associated with additional
HVAC unit 21 stages of heating and cooling are contained in U3.
HVAC unit 21 type data is contalned in U2 in the form of digital
words so as to allow for additional stages of HVAC unit 21 opera-
tion to be activated taking into account whether a Gas/Electric
unit or a Heat Pump unit is being used in the system. Similarly,
U3 contains hi~h/low temperature trip points in the form of digital
words. In the preferred embodiment of the invention, U3 in the
monitor-stat 15 contains high/low trip point data to deactivate
additional stages of heating or cooling: firs~ if a given trip
point setpoint for these stages is exceeded, the entire HVAC unit
21 is deactivated; and if an additional set of high/low trip
points are exceeded by operation of the units' primary stages of
heating or cooling. The digital word data representative of HVAC
unit 21 status thus include data regarding which of the stages of
heating or cooling are energized.
U3 contains instructions for operating the zone dampers
20, 39-41 in the heating mode when the duct temperature is greater
than the actual zone temperature and operating the zone dampers
20, 39-41 in the cooling mode when duct temperature is lower than
actual zone temperature. Instructions in the form of digital words
-35-
~31552
are also present in U3 for generation of a damper command word
by Ul that i9 sent to the monitor-statls damper control system
16 and to all sla~e-stats 30-32 for placing the dampers in the mode
coincident with the decision made at the monitor-stat 15 for
op~ration of the HVAC unit 21 prior to activ~tion of the HVAC
unit 21.
U3 contains instruction codes for placing the dampers
20, 39-41 in the cooling mode! heating mode, or ventilation mode
when the HVAC unit 21 is de-energi~ed by causing Ul to compare
duct temperature with actual temperature; actual temperature
with desired temperature; and duct temperature with predetermined
setpoints (contained in _). Thus, as described above, if there
is no demand in a given zone or a demand different than that com-
puted by a comparison of duct and actual temperature and duct
temperature is within the range 65-80F, the monitor-stat 15
or slave-stat 30-32 will place its damper20, 39-41 in the ventila-
tion~mode.
Any digital word data at any thermostat lO can be trans-
mitted via the SART to any other device. Thus, for example,
the monitor-stat 15 will receive duct temperature data from
every duct temperature sensor 23, 42-44 in the syst~n.The monitor-
stat 15 receives duct temperature data directly via its own
damper board 16 and the A/D convertër in U4. Duct temperature
data in the form of a digital word will be received from each
slave-stat 30-32via the slave-stat 30-32 SART. Accordingly, the
monitor-stat 15 neéd not have the capability of processing a
larye number of duct temperature analog signals through its own
A/D converter in U4, and greatly simplifies the design and pro-
gramming of a given monitor-stat 15.
The thermostat 10 employs a conventional tri-plexed
liquid crystal display 13 that can display data indicative of the
information contained in any digital word data used in the ther-
mostat lO. Furthermore, the monitor-stat 15 has a display 13
and appropriate instruction codes in U3 to allow such display to
provide in~ormation received ~rom any glave-stat 30-32.
-36-
lZ`~3~5;~ -
Turning now to several of the important features o~ the
thermostat according to the invention, an important part of the
operation of thermostat 10, as either a monitor-stat 15 or
slave-stat 30-32, is the use of a serial asynchronous receiver
transmitter ~SART1 contained in U4~ In the preferred embodi-
ment of the invention, the S~RT is similar to a universal asyn-
chronous receiver transmitter (UART) which is restricted to only
operate at a restricted number of data ra~es and a universal type
is not needed in the partlcular applioation.
One use of the SART in a slave-stat 30-32is the reception of
a digital word from the monitor-stat 15 that prevents the tem-
perature setpoints at the slave-stat 3o-32from being changed
locally. A 2-blt word is placed in EEPROM U2 at the slave-stat
30-32 and preventsthe setpoints entered therein from being altered
via switches Sl-S4 at the slave-stat 32. As mentioned previously,
the locking feature override can be enabled locally by entering
a 2-bit word into U2 via switches Sl-S2 and S5 in position "8".
the 2-bit words are used to enable or disable the setpoint lock
` feature.
In the preferred embodiment of the present invention, a
monitor-stat lS is designed to receive information from up to 63
slave-stats 30-32 without the addition of communication bus extender
circuitry. Each sIave-stat 30-32 sends the following information to
the monitor-stat 15 at approximately 20 secbnd intervals: zone
temperature; zone setpoints for heating and cooling; zone damper
position; thermostat mode (heating or cooling); zone address
number; and duct temperature. ~Damper position can be derived
from the signal that a thermostat 10 supplies to the dampar con-
trol circuitry or from damper position-indicating circuitry that
need not be discussed further in this application.)
The input from a realtime clock 14 is received by a slave-stat
30-32 via its SART. Thi9 i5 a 10-bit word. Program periods I
and II are stored as data in U2 as are the se~back setpoints.
Time-of-day program data i9 stored in the Ul RAM. The 10-bit
digital word representative o~ real time i9 read into Ul which
accesseR instructions rom U3 to modify the operation of the
-37-
~35i~;~
slave-s~t 30-32in accordance with time related or programmed
periods. Thus, the sl~ve-stat 30-32will access setback setpoints
from U2 instead of the normal setpoints (also in U2) in response
to the appropriate real time digital words received from a
monitor-stat 15. Also stored in U2 are the digital words for
local (slave-stat3 or remote (monitor-stat) setback control, as
discussed hereinabove.
Data is preprogrammed in U3 for providing the dedicated
set-up setpoints of 81 - 96~F and the dedicated set-back
setpoints of 50 - 65F around the normal setpoint range of 66 - 80F
The thermostats 10, whether used as a monitor-stat 15 or
slave-stat 30-32 receive data from gensors, including sensors 24, 45-47,
23, 42-44 in analog form, and such signals, representing zone
temperature and duct temperature, are converted to digital form
via the A/D converter in U4. When calibrating the temperature
sensor signals, a-bit calibration words are placed in EEPROM U2
via switches Sl and S2 with S5 in "5" (for zone temperature) or
"6" (for duct temperature). Sl or S2 is depressed to raise or
lower the temperature displayed at Display 13 to readout what
the e~act temperature is as measured by a reference device, like
an accurate thermometer. Once set, the calibration words are
placed in U2 and, when Ul/U3 instructions call for enabllng a
sensor to provide temperature data, the calibration word is
sent to A/D converter in U4 which modifies its output to provide
a 10-bit word to U~ that is the exact, calibrated temperature.
This procedure is unique in that the usual methods used for
temperature calibration involve either a modification of the
temperature detector's output signal or the modification of
instrumentation circuitry. In the present invention, calibration
is accomplished by modification of the digital word representa-
tive of the temperature data, the digital word then being sent to
Ul .
U contains a straightforward algorithm for convexsion of
temperature data to readout in F or C on Di~play 13. With S5
in position "3" Sl or S2 can he depressed regulting in the input
into U4 of a digital word that is then placed in U2 Ul, in
-38-
35i5~2
accordance with the algorithm in U3, will compute temperature
in F or C when instructed to do 50 via the word placed in
U2 that was placed therein during programming.
The programs in U3 become time-dependent with proper
program inputs and the addition of a real time input signal
to Ul of the monitor-stat 15 via clock 14. Real time is
transmitted to the slave-stats 30-32 via the SART in monitor-stat
15. The receipt of the time data is used to switch from the
setback or non-occupied time periods and the normal or occupied
time periods established during the original programming. In
addition, the slave-stats 30-32 can be programmed to follow
the setback times of the monitor-stat 15.
The thermostat 10 in accord with the present invention
has instructions and fixed data stored in U3. The information
is placed in U3 in the form of machine code as set forth in
Apendix A for the slave-stat 30-32 and Appendix B for the
monitor-stat 15. The left columns comprise the instruction
addresses and the othercolumns comprise the instructions.
While the invention has been described with respect to
certain specific embodiments, it will be appreciated that many
modifications and changes may be made by those skilled in the
art without departing from the spirit of the invention. It is
intended, therefore, by the appended claims to cover all such
modifications and changes as fall within the true spirit and
scope of the invention.
~ -39-
1~93S5;~:
~ile: SS01_61.COD page: I
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!
4 O
APPl~`NDIX 7~
file: SS81_61.COD page: 2
<IMG>
41
lZ~3~5~
fil~ SS01_61.CO~ p~oe: 3
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IF3Q: FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF ........... ........
IFGa: FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF ........... ........
IFD0: FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF ........... ........
IFEa: FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF ........... ........
IFF8: FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF ........... ........
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