Thermostat with load activation detection feature

• US 6,089,310 A
• Filed: 07/15/1998
• Issued: 07/18/2000
• Est. Priority Date: 07/15/1998
• Status: Expired due to Term

• Current Assignee: Emerson Electric Company
• Original Assignee: Emerson Electric Company
• Inventors: Holohan, Ronald J. Jr., Toth, Bartholomew L.
• Primary Examiner(s): Ford, John K.
• Application Number:
  US09/115,429
• Time in Patent Office: 734 Days
• Field of Search: 62/131, 62/127, 165/11.1, 165/253, 165/259
• US Class Current: 165/11.1
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/32 Responding to malfunctions or emergencies
• CPC Class Codes: F24F 11/37 Resuming operation, e.g. after power outages; Emergency starting
• CPC Class Codes: F24F 11/49 ensuring correct operation, e.g. by trial operation or configuration checks
• CPC Class Codes: F24F 11/52 Indication arrangements, e.g. displays
• CPC Class Codes: F24F 11/67 Switching between heating and cooling modes
• CPC Class Codes: F24F 11/88 Electrical aspects, e.g. circuits
• CPC Class Codes: F24F 2140/00 Control inputs relating to system states
• CPC Class Codes: H01H 47/002 Monitoring or fail-safe circuits

Abstract

A thermostat for control of an AC-operated HVAC unit (or a unit providing only heating or only cooling) is provided with load activation detection sensing for increased reliability of latching relay activation. The thermostat includes a sensing transformer in series with the heating or cooling load (or both, if both are in the system), so that, when activation of the load is called for by the thermostat, current flows in a primary winding of the transformer, inducing a current in the secondary winding. A voltage derived from the current in the secondary winding is sensed by the thermostat controller and used to determine whether the heating or cooling load has been properly activated or deactivated. Sensing of the AC power source in the HVAC unit may also be provided, so that the controller can confirm that the absence of the voltage derived from the current in the secondary winding is actually due to the state of the latching relays rather than to a failure of the AC power source. When the sensed voltage derived from the current in the secondary winding does not correspond to that expected when the latching relays are in their expected states, the thermostat controller provides additional pulses, twice as long in duration as the original pulses and emitted at spaced intervals, to attempt to correct the fault by placing the relays into their correct states. Power for the thermostat controller may be derived, at appropriate times, from the current flowing in the secondary winding.

Claims

1. A thermostat for an environmental temperature control system having an AC system power source, a temperature load comprising one or more members of the group consisting of heating loads and cooling loads to which electrical power from a low voltage side of the AC system power source can be selectively applied through latching relays, the thermostat being operatively coupled to the latching relays to selectively control the application of power from the low voltage side of the AC system power source to the temperature load, the improvement comprising the thermostat having:

a sensor coupled to the temperature load and generating a first indicator signal indicative of power being applied to the load; and

a controller having a load sensing input and a load controlling output, the load sensing input being coupled to the first indicator signal for causing the load controlling output to pulse the latching relays when the sensed power applied to the load does not correspond to that selected by the thermostat.

2. The thermostat of claim 1 wherein the sensor comprises a transformer having a primary winding coupled in a circuit with the temperature load and a secondary winding coupled to the load sensing input, and wherein the first indicator signal is representative of an amount of current in the secondary winding.

3. The thermostat of claim 2 wherein the first indicator signal comprises a rectified, pulsed DC signal derived from current in the secondary winding, and the controller determines whether the pulsed DC signal is present at the load sensing input.

4. The thermostat of claim 3 wherein the secondary winding is configured to supply operating power to the controller when current is induced in the secondary winding.

5. The thermostat of claim 2 and further comprising:

means for generating a second signal indicative of whether the AC system power source is supplying an AC voltage to the thermostat; and

a controller power source for supplying operating current to the controller derived from the AC system power source and including a battery for supplying operating current to the controller when the AC system power source has failed,

the controller being responsive to the second signal for delaying the response to the first indicator signal.

6. The thermostat of claim 5 wherein the means for generating a second signal is coupled to a first node in circuit with the secondary winding and also to a second node in circuit with the primary winding, the first and the second nodes being selected so that, when an AC voltage at the second node is reduced by current flowing in the temperature load, an AC voltage is produced at the first node sufficient for generating the second signal.

7. The thermostat of claim 6 wherein the temperature load comprises both a heating load an a cooling load, and the second node is in circuit between the temperature load and the primary winding.

8. The thermostat of claim 2 and further comprising:

a power supply for supplying power to the controller; and

a first rectifier coupled to the controller power supply,

and further wherein terminals of the environmental temperature control system are coupled to the rectifier so that an AC voltage at the terminals is rectified and the rectified voltage provides a source of power for the power supply.

9. The thermostat of claim 8 and further including a second rectifier coupled to the controller power supply, and wherein the secondary winding is coupled to the second rectifier, the transformer being configured to supply an AC voltage to the second rectifier when the voltage at the terminals is reduced while current flows through the temperature load.

10. The thermostat of claim 9 and further comprising a battery back-up power source supplying current to the power supply when the AC system power source has failed.

11. The thermostat of claim 2 and further comprising an alerting device responsive to current in the secondary winding to provide a perceptible indication of whether the temperature load is powered.

12. A thermostat for an AC-powered environmental temperature control system comprising:

a temperature sensor;

a sensing transformer having a primary winding and a secondary winding, the primary winding being in circuit with a temperature load, so that when power to the temperature load from a low voltage side of the AC-powered environmental temperature control system is switched on, an alternating current flows through the primary winding to thereby induce a voltage across the secondary winding;

a controller coupled to the temperature sensor and configured to provide a signal to selectively switch power to the temperature load in response to the temperature sensor, the controller also being coupled to the secondary winding and configured to sense the voltage across the secondary winding to confirm the switching of power.

13. The thermostat of claim 12 wherein the controller is further configured to repeat a generation of a signal to selectively switch power to the temperature load until the switching of power is confirmed by sensing of the voltage across the secondary winding.

14. The thermostat of claim 13 and further comprising a rectifier, the rectifier being configured to rectify AC current from the environmental control system controlled by the thermostat, and further comprising a battery configured to provide uninterrupted current to the controller in the event of a failure of AC current obtained from the environmental control system.

15. The thermostat of claim 14 and further comprising means for delaying the generation of a signal to selectively switch power to the temperature load when AC current in the environmental control system has failed.

16. A method for controlling an environmental temperature control system with a thermostat, and having a temperature load powered by a low voltage side of the environmental temperature control system, the method comprising:

pulsing a latching relay to control the temperature load to an operating state selected by the thermostat;

sensing a current drawn through the temperature load to generate a signal indicative of an operating state of the temperature load; and

repeating the pulsing step when the signal indicative of the operating state of the temperature load is inconsistent with the selected operating state.

17. The method of claim 16 wherein the sensing step comprises providing inducing a current in the secondary winding of a transformer in series with a switched source of AC power to the temperature load, the current in the secondary winding of the transformer thereby becoming the signal indicative of the operating state of the temperature load.

18. The method of claim 17, further comprising:

supplying the thermostat with a source of power independent of the switched source of AC power to the temperature load;

sensing presence of switchable AC power in the environmental temperature control system; and

delaying the pulsing step, when the switchable AC power has failed, until the switchable AC power has been restored.

19. The method of claim 17, wherein the sensing step comprises rectifying current in the secondary winding to generate a pulsed DC voltage, and applying the pulsed DC voltage to a controller,

and wherein repeating the pulsing step comprises applying pulses to a latching relay in accordance with the presence or absence of the pulsed DC voltage.

20. The method of claim 19, wherein the presence or absence of the pulsed DC voltage is determined periodically by the controller, and the controller periodically generates a pulse when its determination of the presence or absence of the pulsed DC voltage is inconsistent with a required state of the temperature load.

21. The method of claim 20 wherein the periodically generated pulse is longer than a pulse, originally applied by the controller, and which failed to switch the temperature load to the required state.

22. The method of claim 17 further comprising supplying operating current to the controller from current induced in the secondary winding, when the induced current in the secondary winding is present.