Smart fan controller

• US 10,533,768 B2
• Filed: 06/11/2018
• Issued: 01/14/2020
• Est. Priority Date: 04/14/2010
• Status: Active Grant

• Current Assignee: James Lau
• Original Assignee: John Walsh, Robert J. Mowris
• Inventors: Mowris, Robert J., Walsh, John
• Primary Examiner(s): Norman, Marc E
• Application Number:
  US16/005,666
• Publication Number:
  US 20180292102A1
• Time in Patent Office: 582 Days
• CPC Class Codes: F04D 27/004 by varying driving speed
• CPC Class Codes: F24F 11/0001 for ventilation F24F11/30 takes precedence
• CPC Class Codes: F24F 11/46 Improving electric energy efficiency or saving
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: G05D 23/275 with sensing element expanding, contracting, or fusing in response to changes of temperature
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

The efficient fan controller includes a microprocessor receiving at least one signal input from thermostat/equipment control terminals to control a fan relay to operate a system fan. The microprocessor monitors a thermostat call for cooling/heating duration and determines a variable fan-off delay based on the cooling/heating cycle duration, and at an end of a cooling/heating cycle energize the fan relay to operate the system fan for the variable fan-off delay. The fan controller avoids false thermostat activation signals and includes a common wire adapter to provide continuous power to a smart communicating thermostat and is configured to evaluate floating, zero, rectified, false positive and active input signals. The fan controller can be embodied on a forced-air-unit control board or thermostat. The fan controller installation methods ensure the system fan/blower operates at high speed for heating and cooling to improve thermal comfort, efficiency and satisfy the thermostat sooner to save energy.

Claims

1. A smart fan controller (817) for a Heating Ventilation Air Conditioning (HVAC) system, comprising:

a microprocessor (304);

a thermostat element (806) configured to receive a first analog control signal (341) and a second analog control signal (342) from a thermostat (201 or 800), where the thermostat element (806) is configured to rectify and combine the first analog control signal (341) and the second analog control signal (342) into a third analog control signal (343);

an HVAC element (814) configured to receive the third analog control signal (343) from thermostat element (806) and provide a fourth digital control signal (344) to the microprocessor (304) in response to the third analog control signal (343);

an Alternating Current to Direct Current (AC-DC) converter (303) configured to provide a fifth digital timing control signal (345) to the microprocessor (304) synchronous with a low voltage power signal from a system transformer (210);

a signal conditioning element (308) configured to receive an at least one sixth analog control signal (346) from the thermostat (201 or 800) and convert the at least one sixth analog control signal (346) to an at least one seventh digital control signal (347) provided to the microprocessor (304) wherein the at least one seventh digital control signal (347) is selected from the group consisting of;

a digital fan signal, a digital AC/HP compressor signal, and a digital heat signal;

a first switching device (836) configured with a wired electrical output (212) or a wireless (WIFI) communication channel (847) for the microprocessor (304) to use an eighth digital control signal (348) to energize or de-energize at least one HVAC device (340) selected from the group consisting of;

an AC/HP compressor (203), a HP reversing valve (263 or 264), and a heat source (202);

a second switching device (301) configured with a wired electrical output (212) or a wireless (WIFI) communication channel (847) for the microprocessor (304) to use a ninth digital control signal (349) to energize or de-energize a fan relay (205);

wherein the microprocessor (304) is further configured to perform at least one action selected from the group consisting of;

monitor a cooling cycle duration and determine a variable fan-off delay time based on the cooling cycle duration and at an end of the cooling on cycle, either activate or continue to active the ninth digital control signal (349) to operate the fan relay (205) until the variable fan-off delay time has expired; and

monitor a heating cycle duration and determine the variable fan-off delay time based on the heating cycle duration and at an end of a heating on cycle, either activate or continue to activate the ninth digital control signal (349) to operate the fan relay (205) until the variable fan-off delay time has expired.

2. The smart fan controller (817) of claim 1, wherein the first analog control signal (341) and the second analog control signal (342) are selected from the group consisting of:

an analog fan signal, an analog Air Conditioning/Heat Pump (AC/HP) compressor signal, and an analog heat signal from a thermostat (201 or 800).

3. The smart fan controller (817) of claim 1, wherein a repurposed wire (810) is used to carry the third analog control signal (343) from the thermostat element (806) to the HVAC element (814).

4. The smart fan controller (817) of claim 1, wherein the fourth digital control signal (344) from the HVAC element (814) is at least one signal selected from the group consisting of:

a zero Volts Direct Current (VDC) digital signal if there is a positively or negatively rectified signal from the thermostat element (806) and a non-zero VDC digital signal if there is no signal from the thermostat element (806).

5. The smart fan controller (817) of claim 1, wherein the low voltage power signal from the system transformer (210) converted by the AC-DC converter (303) is a 24 Volts Alternating Current (VAC) 60 Hertz (Hz) power signal from the system transformer (210).

6. The smart fan controller (817) of claim 1, wherein the first switching device (836) is energized by the eighth digital control signal (348) from the microprocessor (304), if the microprocessor determines that the first analog control signal (341) from the thermostat (201 or 800) is active or the second analog control signal (342) from the thermostat (201 or 800) is active.

7. The smart fan controller (817) of claim 1, wherein the first switching device (836) is energized by the eighth digital control signal (348) from the microprocessor (304), if the microprocessor determines that the fourth digital control signal (344) from the HVAC element (814) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge.

8. The smart fan controller (817) of claim 1, wherein the second switching device (301) is energized by the ninth digital control signal (349) from the microprocessor (304), if the microprocessor determines that at least one control signal combination is met where the at least one control signal combination is selected from the group consisting of:

the fourth digital control signal (344) from the HVAC element (814) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) immediately,

the fourth digital control signal (344) from the HVAC element (814) is non-zero VDC and the digital heat signal from the signal conditioning element (308) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) at the end of the heating on cycle or after an initial fan-on delay,

the digital fan signal or the digital AC/HP signal from the signal conditioning element (308) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) immediately, and

the digital fan signal from the signal conditioning element (308) is non-zero VDC and the fourth digital control signal (344) from the HVAC element (814) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) at the end of the heating on cycle or after an initial fan-on delay.

9. The smart fan controller (817) of claim 1, wherein the second switching device (301) is energized by the ninth digital control signal (349) from the microprocessor (304), if the microprocessor determines at least one control signal combination is met where the at least one control signal combination is selected from the group consisting of:

the analog fan signal from the thermostat (201 or 800) is active wherein the microprocessor energizes the second switching device (301) immediately, and

the analog heat signal is active when the analog fan signal from the thermostat (201 or 800) and the analog AC/HP signal from the thermostat (201 or 800) are inactive wherein the microprocessor (304) activates the ninth digital control signal (349) at the end of the heating on cycle or after an initial fan-on delay.

10. The smart fan controller (817) of claim 1, wherein the cooling cycle comprises at least one cooling cycle selected from the group consisting of:

a cooling on cycle, and a cooling off cycle.

11. The smart fan controller (817) of claim 1, wherein the heating cycle comprises at least one heating cycle selected from the group consisting of:

a heating on cycle, and a heating off cycle.

12. The smart fan controller (817) of claim 1, wherein the signal conditioning element (308) includes at least one electrical input (845) having at least one Zener diode between the at least one electrical input (845) and an optoisolator (856) to differentiate an active analog thermostat control signal from a stray voltage signal in order to deliver a correct digital control signal to the microprocessor (304).

13. The smart fan controller (817) of claim 1, wherein the smart fan controller (817) is embodied in a Forced Air Unit (FAU) control board (293) or the thermostat (201 or 800).

14. The smart fan controller (817) of claim 1, wherein the system fan/blower (206) is controlled to a higher fan speed, higher than a lower fan speed used for heating, when the thermostat Fan G (204) signal is energized in cooling or heating modes based on at least one mechanism selected from the group consisting of:

a high-voltage Y-adapter (842) configured to combine two high-voltage signal outputs from a Forced Air Unit (FAU) control board (238) to enable the higher fan speed,

a wired or wireless (WIFI) software application (846) configured to command a switching device to enable the higher fan speed, and

a fan speed controller configured to identify an electrical signal waveform (848) when the thermostat G terminal is energized to enable the higher fan speed.

15. The smart fan controller (817) of claim 1, wherein a load resistor (852) is provided between the system transformer common (210a) and the smart fan controller (817) electrical inputs to avoid false thermostat activation signals for the system fan/blower (206).

16. The smart fan controller (817) of claim 1, wherein the microprocessor (304) is configured to:

monitor signals present or absent on a thermostat or equipment terminal (201) or a smart communicating thermostat (800) with a fan control having an AUTO setting and a fan-only ON setting to perform a fan-only Fault Detection Diagnostic (FDD) procedure;

detect and monitor the fan-only ON setting based on the presence of a fan signal and the absence of;

a heat signal, a cool signal, and a fan signal during a fan-off delay;

correct a fan-only ON setting fault by de-energizing a fan relay (205) to override the fan-only ON setting after a Threshold Fan-on Time (TFT) has expired based on the presence throughout the TFT of the fan signal with or without a thermostat call for cooling or heating.

17. The smart fan controller (817) of claim 16, wherein the fan controller TFT can vary from 0 to 60 minutes.

18. A smart fan controller (817) for a Heating Ventilation Air Conditioning (HVAC) system, comprising:

a microprocessor (304);

a thermostat element (806) configured to receive a first analog control signal (341) and a second analog control signal (342) from a thermostat (201 or 800), where the thermostat element (806) is configured to rectify and combine the first analog control signal (341) and the second analog control signal (342) into a third analog control signal (343);

an HVAC element (814) configured to receive the third analog control signal (343) from thermostat element (806) and provide a fourth digital control signal (344) to the microprocessor (304) in response to the third analog control signal (343);

an Alternating Current to Direct Current (AC-DC) converter (303) configured to provide a fifth digital timing control signal (345) to the microprocessor (304) synchronous with a low voltage power signal from a system transformer (210);

a signal conditioning element (308) configured to receive at least one sixth analog control signal (346) from the thermostat (201 or 800) and convert the at least one sixth analog control signal (346) to an at least one seventh digital control signal (347) provided to the microprocessor (304) wherein the at least one seventh digital control signal (347) is selected from the group consisting of;

a digital fan signal, a digital AC/HP compressor signal, and a digital heat signal;

at least one electrical input for at least one temperature sensor measurement used by the microprocessor (304) to monitor at least one air temperature;

a first switching device (836) configured with a wired electrical output (212) or a wireless (WIFI) communication channel (847) for the microprocessor (304) to use an eighth digital control signal (348) to energize or de-energize at least one HVAC device (340) selected from the group consisting of;

an AC/HP compressor (203), a HP reversing valve (263 or 264), and a heat source (202);

a second switching device (301) configured with a wired electrical output (212) or a wireless (WIFI) communication channel (847) for the microprocessor (304) to use a ninth digital control signal (349) to energize or de-energize a fan relay (205);

wherein the microprocessor (304) is further configured to perform at least one action selected from the group consisting of;

monitor a cooling cycle duration and determine a variable fan-off delay time based on the cooling cycle duration and at an end of the cooling on cycle, either activate or continue to active the ninth digital control signal (349) to operate the fan relay (205) until the variable fan-off delay time has expired;

monitor a heating cycle duration and determine the variable fan-off delay time based on the heating cycle duration and at an end of a heating on cycle, either activate or continue to activate the ninth digital control signal (349) to operate the fan relay (205) until the variable fan-off delay time has expired; and

monitor the temperature sensor measurement, and at an end of the cooling cycle or heating cycle either energize or continue to energize the switching device (301) and the fan relay (205) to operate a system fan/blower (206) for the variable fan-off delay time to deliver additional cooling or heating energy to a conditioned space wherein the variable fan-off delay time is based on at least one Conditioned Space Temperature (CST) measurement threshold selected from the group consisting of;

the CST reaches a heating fan-off delay differential offset (363), the CST reaches a cooling fan-off delay differential offset (374), and the CST reaches an inflection point where the rate of change of the CST with respect to time equals zero plus or minus a confidence interval tolerance.

19. The smart fan controller (817) of claim 18, wherein the heating fan-off delay differential offset (363) is within plus or minus 0.5 degrees Fahrenheit of the CST at the end of the thermostat call for heating which is equivalent to an upper limit thermostat differential temperature where the thermostat terminates a call for heating.

20. The smart fan controller (817) of claim 18, wherein the cooling fan-off delay differential offset (374) is within plus or minus 0.5 degrees Fahrenheit of the CST at the end of the thermostat call for cooling which is equivalent to a lower limit thermostat differential temperature where the thermostat terminates a call for cooling.

21. The smart fan controller (817) of claim 18, wherein the first analog control signal (341) and the second analog control signal (342) are selected from the group consisting of:

an analog fan signal, an analog Air Conditioning/Heat Pump (AC/HP) compressor signal, and an analog heat signal from a thermostat (201 or 800).

22. The smart fan controller (817) of claim 18, wherein a repurposed wire (810) previously used to carry a single analog signal from the thermostat element (806) to HVAC Equipment Control Terminals 804, is used to carry the third analog control signal (343) from the thermostat element (806) to the HVAC element (814).

23. The smart fan controller (817) of claim 18, wherein the fourth digital control signal (344) from the HVAC element (814) is at least one signal selected from the group consisting of:

a zero Volts Direct Current (VDC) digital signal if there is a positively or negatively rectified signal from the thermostat element (806) and a non-zero VDC digital signal if there is no signal from the thermostat element (806).

24. The smart fan controller (817) of claim 18, wherein the low voltage power signal from the system transformer (210) converted by the AC-DC converter (303) is a 24 Volts Alternating Current (VAC) 60 Hertz (Hz) power signal from the system transformer (210).

25. The smart fan controller (817) of claim 18, wherein the first switching device (836) is energized by the eighth digital control signal (348) from the microprocessor (304), if the microprocessor determines that the first analog control signal (341) from the thermostat (201 or 800) is active or the second analog control signal (342) from the thermostat (201 or 800) is active.

26. The smart fan controller (817) of claim 18, wherein the first switching device (836) is energized by the eighth digital control signal (348) from the microprocessor (304), if the microprocessor determines that the fourth digital control signal (344) from the HVAC element (814) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge.

27. The smart fan controller (817) of claim 18, wherein the second switching device (301) is energized by the ninth digital control signal (349) from the microprocessor (304), if the microprocessor determines that at least one control signal combination is met where the at least one control signal combination is selected from the group consisting of:

the fourth digital control signal (344) from the HVAC element (814) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) immediately,

the fourth digital control signal (344) from the HVAC element (814) is non-zero VDC and the digital heat signal from the signal conditioning element (308) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) at the end of the heating on cycle or after an initial fan-on delay,

the digital fan signal or the digital AC/HP signal from the signal conditioning element (308) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) immediately, and

the digital fan signal from the signal conditioning element (308) is non-zero VDC and the fourth digital control signal (344) from the HVAC element (814) is zero VDC during a time when the fifth digital timing control signal (345) from the AC-DC converter (303) transitions to a positive or a negative edge wherein the microprocessor (304) activates the ninth digital control signal (349) at the end of the heating on cycle or after an initial fan-on delay.

28. The smart fan controller (817) of claim 18, wherein the second switching device (301) is energized by the ninth digital control signal (349) from the microprocessor (304), if the microprocessor determines at least one control signal combination is met selected from the group consisting of:

the analog fan signal from the thermostat (201 or 800) is active wherein the microprocessor energizes the second switching device (301) immediately, and

the analog heat signal is active when the analog fan signal from the thermostat (201 or 800) and the analog AC/HP signal from the thermostat (201 or 800) are inactive wherein the microprocessor (304) activates the ninth digital control signal (349) at the end of the heating on cycle or after an initial fan-on delay.

29. The smart fan controller (817) of claim 18, wherein the cooling cycle is selected from the group consisting of:

a cooling on cycle, and a cooling off cycle.

30. The smart fan controller (817) of claim 18, wherein the heating cycle is selected from the group consisting of:

a heating on cycle, and a heating off cycle.

31. The smart fan controller (817) of claim 18, wherein the signal conditioning element (308) includes at least one electrical input (845) having at least one Zener diode between the at least one electrical input (845) and an optoisolator (856) to differentiate an active analog thermostat control signal from a stray voltage signal in order to deliver a correct digital control signal to the microprocessor (304).

32. The smart fan controller (817) of claim 18, wherein the smart fan controller (817) is embodied in a Forced Air Unit (FAU) control board (293) or the thermostat (201 or 800).

33. The smart fan controller (817) of claim 18, wherein the system fan/blower (206) is controlled to a higher fan speed, higher than a lower fan speed used for heating, when the thermostat Fan G (204) signal is energized in cooling or heating modes based on at least one mechanism selected from the group consisting of:

a high-voltage Y-adapter (842) configured to combine two high-voltage signal outputs from a Forced Air Unit (FAU) control board (238) to enable the higher fan speed,

a wired or wireless (WIFI) software application (846) configured to command a switching device to enable the higher fan speed, and

a fan speed controller configured to identify an electrical signal waveform (848) when the thermostat G terminal is energized to enable the higher fan speed.

34. The smart fan controller (817) of claim 18, wherein a load resistor (852) is provided between the system transformer common (210a) and the smart fan controller (817) electrical inputs to avoid false thermostat activation signals for the system fan/blower (206).

35. The smart fan controller (817) of claim 18, wherein the microprocessor (304) is configured to:

monitor signals present or absent on a thermostat or equipment terminal (201) or a smart communicating thermostat (800) with a fan control having an AUTO setting and a fan-only ON setting to perform a fan-only Fault Detection Diagnostic (FDD) procedure;

detect and monitor the fan-only ON setting based on the presence of a fan signal and the absence of;

a heat signal, a cool signal, and a fan signal during a fan-off delay;

correct a fan-only ON setting fault by de-energizing a fan relay (205) to override the fan-only ON setting after a Threshold Fan-on Time (TFT) based on the presence throughout the TFT of the fan-only signal with or without a thermostat call for cooling or heating.

36. The smart fan controller (817) of claim 35, wherein the fan controller TFT can vary from 0 to 60 minutes.

37. A smart fan controller for a Heating Ventilation Air Conditioning (HVAC) system, comprising:

a microprocessor (304);

at least one electrical input (845) to receive at least one HVAC control signal (341) from a thermostat or equipment control terminal (201) or a smart communicating thermostat (800) wherein the at least one HVAC control signal (341) is selected from the group consisting of;

a fan signal, an Air Conditioning/Heat Pump (AC/HP) compressor signal, and a heat signal;

a signal conditioning element (308) configured to receive the at least one HVAC control signal (341) and convert the at least one HVAC control signal (341) to at least one digital control signal (347) provided to the microprocessor (304) wherein the at least one digital HVAC control signal (347) is selected from the group consisting of;

a digital fan signal, a digital AC/HP compressor signal, and a digital heat signal;

an Alternating Current to Direct Current (AC-DC) converter (303) configured to provide a digital timing control signal (345) to the microprocessor (304) synchronous with a low voltage power signal from a system transformer (210);

a switching device (301) configured with a wired electrical output (212) or a wireless (WIFI) communication channel (847) for the microprocessor (304) to energize or de-energize a fan relay (205);

wherein the microprocessor (304) is further configured to perform at least one action selected from the group consisting of;

monitor a cooling cycle duration and determine a variable fan-off delay time based on the cooling cycle duration and at an end of the cooling on cycle, either energize or continue to energize the fan relay (205) until the variable fan-off delay time has expired in order to improve energy efficiency; and

monitor a heating cycle duration and determine the variable fan-off delay time based on the heating cycle duration and at an end of a heating on cycle, either energize or continue to energize fan relay (205) until the variable fan-off delay time has expired in order to improve energy efficiency.

38. The smart fan controller of claim 37, wherein the low voltage power signal from the system transformer (210) converted by the AC-DC converter (303) is a 24 Volts Alternating Current (VAC) 60 Hertz (Hz) power signal from the system transformer (210).

39. The smart fan controller of claim 37, wherein the switching device (301) is energized by the microprocessor (304), if the microprocessor determines that at least one control signal combination is met where the at least one control signal combination is selected from the group consisting of:

the digital fan signal is zero VDC, during a time when the digital timing HVAC control signal (345) transitions to a positive or a negative edge wherein the microprocessor (304) energizes the switching device (301) and the fan relay (205) immediately, and

the digital fan signal is non-zero VDC and the digital heat signal is zero VDC during a time when the digital timing HVAC control signal (345) transitions to a positive or a negative edge wherein the microprocessor (304) energizes the switching device (301) and the fan relay (205) at the end of a heating on cycle or after an initial fan-on delay.

40. The smart fan controller of claim 37, wherein the switching device (301) is energized by the microprocessor (304), if the microprocessor determines at least one control signal combination is met where the at least one control signal combination is selected from the group consisting of:

the fan signal is active wherein the microprocessor energizes the switching device (301) immediately, and

the heat signal is active when the fan signal is inactive or the AC/HP signal is inactive wherein the microprocessor (304) energizes the switching device (301) at the end of the heating on cycle or after an initial fan-on delay.

41. The smart fan controller of claim 37, wherein the cooling cycle is selected from the group consisting of:

a cooling on cycle, and a cooling off cycle.

42. The smart fan controller of claim 37, wherein the heating cycle is selected from the group consisting of:

a heating on cycle, and a heating off cycle.

43. The smart fan controller of claim 37, wherein the signal conditioning element (308) includes at least one electrical input (845) having at least one Zener diode between the at least one electrical input (845) and an optoisolator (856) to differentiate an active analog thermostat control signal from a stray voltage signal in order to deliver a correct digital control signal to the microprocessor (304).

44. The smart fan controller of claim 37, wherein the smart fan controller is embodied in a Forced Air Unit (FAU) control board (293) or a thermostat (201 or 800).

45. The smart fan controller of claim 37, wherein the system fan/blower (206) is controlled to a higher fan speed, higher than a lower fan speed used for heating, when the thermostat Fan G (204) signal is energized in cooling or heating modes based on at least one mechanism selected from the group consisting of:

a high-voltage Y-adapter (842) configured to combine two high-voltage signal outputs from a Forced Air Unit (FAU) control board (238) to enable the higher fan speed,

a wired or wireless (WIFI) software application (846) configured to command a switching device to enable the higher fan speed, and

a fan speed controller configured to identify an electrical signal waveform (848) when the thermostat G terminal is energized to enable the higher fan speed.

46. The smart fan controller of claim 37, wherein a load resistor (852) is provided between the system transformer common (210a) and the smart fan controller electrical inputs to avoid false thermostat activation signals for the system fan/blower (206).

47. The smart fan controller of claim 37, wherein the microprocessor (304) is configured to:

monitor signals present or absent on a thermostat or equipment terminal (201) or a smart communicating thermostat (800) with a fan control having an AUTO setting and a fan-only ON setting to perform a fan-only Fault Detection Diagnostic (FDD) procedure;

detect and monitor the fan-only ON setting based on the presence of a fan signal and the absence of;

a heat signal, a cool signal, and a fan signal during a fan-off delay;

correct a fan-only ON setting fault by de-energizing a fan relay (205) to override the fan-only ON setting after a Threshold Fan-on Time (TFT) based on the presence throughout the TFT of the fan-only signal with or without a thermostat call for cooling or heating.

48. The smart fan controller of claim 47, wherein the fan controller TFT can vary from 0to 60 minutes.

49. A smart fan controller for a Heating Ventilation Air Conditioning (HVAC) system, comprising:

a microprocessor (304);

at least one wired electrical input (845) or a wireless (WIFI) communication channel (847) to receive at an least one HVAC control signal (341) from a thermostat or equipment control terminal (201) or a smart communicating thermostat (800), wherein the at least one HVAC control signal (341) is selected from the group consisting of;

a fan signal, an Air Conditioning/Heat Pump (AC/HP) compressor signal, and a heat signal;

a signal conditioning element (308) configured to receive the at least one HVAC control signal (341) and convert the at least one HVAC control signal (341) to at least one digital control signal (347) provided to the microprocessor (304) wherein the at least one digital HVAC control signal (347) is selected from the group consisting of;

a digital fan signal, a digital AC/HP compressor signal, and a digital heat signal;

an Alternating Current to Direct Current (AC-DC) converter (303) configured to provide a digital timing control signal (345) to the microprocessor (304) synchronous with a low voltage power signal from a system transformer (210);

a switching device (301) configured with a wired electrical output (212) or a wireless (WIFI) communication channel (847) for the microprocessor (304) to energize or de-energize a fan relay (205);

wherein the microprocessor (304) is configured to;

monitor signals present or absent on a thermostat or equipment terminal (201) or a smart communicating thermostat (800) with a fan control having an AUTO setting and a fan-only ON setting to perform a fan-only Fault Detection Diagnostic (FDD) procedure;

detect and monitor the fan-only ON setting based on the presence of a fan signal and the absence of;

a heat signal, a cool signal, and a fan signal during a fan-off delay;

correct a fan-only ON setting fault by de-energizing a fan relay (205) to override the fan-only ON setting after a Threshold Fan-on Time (TFT) based on the presence throughout the TFT of the fan-only signal with or without a thermostat call for cooling or heating.

50. The smart fan controller of claim 49, wherein the fan controller TFT can vary from 0to 60 minutes.