(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2005/0040250 A1
`Wruck
`(43) Pub. Date:
`Feb. 24, 2005
`
`US 2005004O250A1
`
`(54) TRANSFER OF CONTROLLER
`CUSTOMIZATIONS
`(76) Inventor: Richard A. Wruck, Mount Prospect, IL
`(US)
`Correspondence Address:
`HONEY WELL INTERNATIONAL INC.
`101 COLUMBIA ROAD
`PO BOX 2.245
`MORRISTOWN, NJ 07962-224.5 (US)
`(21) Appl. No.:
`10/859,665
`(22) Filed:
`Jun. 3, 2004
`Related U.S. Application Data
`(63) Continuation-in-part of application No. 10/643,395,
`filed on Aug. 18, 2003.
`Continuation-in-part of application No. 10/643,430,
`filed on Aug. 18, 2003.
`
`Publication Classification
`
`(51) Int. Cl. ............................. F23N 5/20; G05D 23/00
`
`(52) U.S. Cl. ................................................................ 236/51
`
`(57)
`
`ABSTRACT
`
`A device and method that may be used at nearly any place
`to Set and adjust a control System Such as a thermostat,
`controller or computer having numerous parameters and
`options that may be selected for desired operation of an air
`management System. One may remotely, via a personal
`digital assistant or computer, configure, commission, Select,
`Set or adjust the parameters and options of a control System.
`The configuration information may be shared with other
`personal digital assistants in a wireleSS or non-wireleSS
`manner. Further, enhanced diagnostics and repair may be
`achieved with the Sending of configuration information from
`one PDA or computer to a PDA or computer at a diagnostic
`and repair facility. New modifications and calibration may
`be provided for the configuration. Such added information
`and configuring may be sent back to the originating PDA or
`computer for the providing to the controller or thermoStat.
`
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`I
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`RS232 Interface
`
`Communicating
`Subbase
`
`
`
`SensOrs
`
`12
`
`Air
`Management
`System
`
`Installer Configuration Tool
`
`PC Laptop effice 1
`or A / 2.
`
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`Patent Application Publication Feb. 24, 2005 Sheet 1 of 41
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`US 2005/004O250 A1
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`Patent Application Publication Feb. 24, 2005 Sheet 2 of 41
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`US 2005/004O250 A1
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`Patent Application Publication Feb. 24, 2005 Sheet 5 of 41
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`Patent Application Publication Feb. 24, 2005 Sheet 9 of 41
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`Patent Application Publication Feb. 24, 2005 Sheet 16 of 41
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`US 2005/004O250 A1
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`Start
`
`16
`
`Contractor Enters
`PhOne Number
`and Logo Graphic
`On PC
`
`
`
`
`
`17
`
`Graphic proper
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`18
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`Convert Graphic
`format
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`Transfer Data from PC to
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`stick)
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`via PDA using an easy wire,
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`smartmedia, compact flash,
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`Patent Application Publication Feb. 24, 2005 Sheet 17 of 41
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`US 2005/004O250 A1
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`31
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`Air Management
`System Equipment
`Controls
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`28
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`Serial Communications
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`base, development tools,
`tester, etc.)
`
`56
`
`Device
`
`36
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`Device to download
`firmware to the
`thermostat
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`Therrnostat
`with human
`interface
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`
`
`
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`External
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`Figure 16
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`Patent Application Publication Feb. 24, 2005 Sheet 18 of 41
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`US 2005/004O250 A1
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`Patent Application Publication Feb. 24, 2005 Sheet 19 of 41
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`US 2005/004O250 A1
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`Patent Application Publication Feb. 24, 2005 Sheet 20 of 41
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`US 2005/004O250 A1
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`85
`
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`
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`POWER WITHN
`ACCEPTABLE
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`NEATE POWERSHUT-DOWN
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`SAWESCHEDULE
`SAVE CONFECURATION
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`Patent Application Publication Feb. 24, 2005 Sheet 21 of 41
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`US 2005/0040250 A1
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`Patent Application Publication Feb. 24, 2005 Sheet 22 of 41
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`Patent Application Publication Feb. 24, 2005 Sheet 23 of 41
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`US 2005/004O250 A1
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`Patent Application Publication Feb. 24, 2005 Sheet 24 of 41
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`Patent Application Publication Feb. 24, 2005 Sheet 25 of 41
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`Patent Application Publication Feb. 24, 2005 Sheet 28 of 41
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`US 2005/0040250 A1
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`PETITIONER GOOGLE EX. 1005
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`

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`Patent Application Publication Feb. 24, 2005 Sheet 29 of 41
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`US 2005/0040250 A1
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`US 2005/004O250 A1
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`Patent Application Publication Feb. 24,2005 Sheet 32 of 41
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`Patent Application Publication Feb. 24, 2005 Sheet 33 of 41
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`US 2005/0040250 A1
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`351
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`Patent Application Publication Feb. 24, 2005 Sheet 34 of 41
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`Patent Application Publication Feb. 24, 2005 Sheet 40 of 41
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`US 2005/0040250A1
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`Patent Application Publication Feb. 24, 2005 Sheet 41 of 41
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`PETITIONER GOOGLE EX. 1005
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`US 2005/004O250 A1
`
`Feb. 24, 2005
`
`TRANSFER OF CONTROLLER
`CUSTOMIZATIONS
`0001. The present invention is a Continuation-in-Part of
`U.S. patent application Ser. No. 10/643,395, filed Aug. 18,
`2003, by P. Wacker et al. and entitled “PDACONFIGURA
`TION OF THERMOSTATS". The present invention is a
`Continuation-in-Part of U.S. patent application Ser. No.
`10/643,430, filed Aug. 18, 2003, by P. Wacker et al. and
`entitled “PDA DIAGNOSIS OF THERMOSTATS.
`
`BACKGROUND
`0002 The present invention pertains to controllers and
`particularly to thermostats and the control of air manage
`ment Systems. More particularly, it pertains to the use of
`configuration tools for configuring, Setting and adjusting of
`programmable thermostats of air management Systems, and
`the transfer of configuration information among the con
`figuration tools.
`0003. The setting and adjusting of air management sys
`tem thermostats, especially programming thermostats, to
`control air conditioning, heating, humidity, Volume of
`moved air, and the like, may have Settings and conditions
`that determine which equipment is modulated, turned on or
`off, and for when and what duration. Many commercial and
`residential places may have complex and confusing controls
`for air management Systems which have features Such as
`programmable thermostats. Some proprietors may obtain a
`programmable control System for controlling heating and
`cooling in their buildings. However, they may have frustra
`tions with the adjusting and operating those kinds of Systems
`and often Stop trying to take advantage of certain control
`features of the Systems. An installer may initially Set a
`System up and get it operating Satisfactorily; however, the
`adjusting and Setting the System may not be easy for the new
`recipient or owner of the System because of the apparent
`complexity, user unfriendliness, and the lack of convenient
`and Sufficient time to learn, Set and adjust various parameters
`of the System for controlling, for instance, heating, ventila
`tion and air conditioning (HVAC).
`
`SUMMARY
`0004. The configuration of thermostats minimizes the
`issueS of complexities, user unfriendliness, and the amount
`of time and convenience involved in Setting up, adjusting
`and controlling an air management System, Such as an air
`handling and conditioning System. A remote configuration
`tool makes it possible for one at a convenient time at nearly
`any place to Set and adjust a thermostat, controller or
`computer having numerous parameters and options that may
`be selected for a desired operation of the air management
`System. One does not need to be at the thermostat, controller
`or computer of the air management System to configure, Set
`or adjust the parameters of it. The parameters may include,
`but not be limited to, temperatures, humidity, Sensor Selec
`tion, Volume of air movement, fan or air mover behavior
`Such as continuous or intermittent and Speed, the percentage
`of added fresh air, Stages of cooling and heating at various
`Zones, control of heat pumps, heaters and air conditioners,
`modes of occupied, unoccupied or Standby of respective
`Spaces in a building, for day and night, between Specific
`times, at certain days, for certain buildings at Specific
`locations. The configuration tool may easily enable one to
`
`easily and conveniently achieve these tasks with an inter
`facing of a PDA (viz., a personal digital assistant used as a
`configuration tool) to the control System. These tasks may be
`accomplished on a PDA in an armchair remote from the
`facility with the air management System. Configuration on a
`PDA may be transferred and shared with other PDAs for the
`convenience of configuring other thermostats, repairing con
`figurations or other things.
`0005 There may be minimization of inconvenience
`involved in commissioning, testing and diagnosing a ther
`most at System. A personal digital assistant (PDA) may be
`used thus significantly easing Such activities. PDA-based on
`line diagnostics may automatically discover the thermostat
`configuration, turn off normal controller delays, temporary
`override Sensor inputs and Set points, and Verify proper
`output action including the monitoring the discharge air
`temperature for the resulting temperature behavior based on
`the equipment Stages activated. Problems discovered are
`reported, automatically recorded and the original operating
`parameters can be restored. This means that leSS expertise
`may be required the technicians Sent to install and trouble
`shoot thermostat installations. The diagnostic application
`may minimize the issueS of complexities, user unfriendli
`neSS, and the amount of time.
`0006 A program with configuration information may be
`uploaded to the PDA from a controller of an air handling and
`conditioning system, such as the HVAC. Such controller
`may be Similar to a programmable thermostat having adjust
`ment and Settings for controlling the parameters of the
`System. All of the items that need to be done for configuring,
`Setting, adjusting and controlling a System via the thermo
`Stat, controller or computer may be done on a PDA at any
`time at a location as desired, possibly remote from the
`building having the system. Whether at the office, home or
`other place, one may configure, Set and adjust, among other
`things, with the PDA, parameters and actions of a controller
`relative to various air management Systems at different
`facilities. Programmed configurations, Settings, adjustments
`and the like may be done with the PDA. Then one may take
`the PDA and go to the various thermostats, controllers,
`computers or other air management System control devices
`and upload the programs Specific to the respective Systems.
`These may be placed in memory. One interface connection
`for the uploading and downloading between the PDA and
`the thermostat, controller or computer of the air management
`System may be an infrared (IR) connection. One may obtain
`a PDA that is readily available in stores, such as a PalmTM,
`or the like, and take it to a thermostat, controller, computer
`or control module of the air management System and upload
`a program, including the configuration and the Settings the
`System. Then one may deal with various configurations,
`Settings, adjustments and related activities as desired relative
`to the parameters of the air management System and then
`download any changes to the respective thermostat, control
`ler, computer or control module of the System.
`0007. The interfacing between the PDA or similar com
`mercially available device and the controller or thermostat
`may also be done via radio frequency communications (Such
`as Bluetooth or Wi-Fi), electrical lines such as the telephone,
`or optical fiber Systems. The internet, Ethernet, or intranet in
`its various aspects may be used for interfacing between the
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`US 2005/004O250 A1
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`
`PDA and the controller or thermostat. Other forms of
`interfacing between the PDA and the system may be imple
`mented.
`0008. A technical person, installer, representative or tech
`nician, trained for configuring, Setting and adjusting control
`mechanisms of air management System thermostats, may go
`to various buildingS Such as Stores, factories or offices and do
`control changes for the air management Systems of those
`places. The control mechanism of the air management
`System of each place may have its own Specific configura
`tion and settings which may be different from the others. The
`technician may go from place to place and download Spe
`cific configurations and Settings with the PDA very quickly
`and efficiently to the air management System thermostats at
`these places.
`0009 Even though there are many ways that program
`mable thermostats, controllers, control mechanisms, com
`puters, control modules or their equivalents (hereinafter
`each of these may be referred to as a “thermostat”) of air
`management Systems may be communicated with, relative
`to the Setting and configuration inputs, the PDA using the
`infrared interface is inexpensive and easily adaptable. Many
`individuals have a PDA of one kind or another which may
`have an infrared or direct connection port. No modification
`is of these devices needed to use them as configuration tools.
`One merely may go to the respective thermostat with a PDA
`and upload a program that has the appropriate protocol,
`configuration and Setting information of the System. Then
`one may enter the desired Settings, adjustments and Schedule
`information relative to the control of the air management
`system. The information is presented on the PDA in a clear
`and Step by Step instructive manner. And as indicated above,
`the PDA may contain numerous and differing configurations
`and Settings applicable to Specific Systems at different
`places. Anyone with a PDA or the like may participate in this
`program. However, there may be Security measures requir
`ing codes or other permission granting procedures So that the
`integrity of the control of air management Systems may be
`maintained.
`0010. An installer's configuring of high end program
`mable commercial thermostats has become very complex
`due to all of the features that can be implemented by low cost
`microprocessors. There is a trade-off between the ease of use
`and the complexity of the user interface. Configuring might
`be done only once by the installer and then usually is not
`required again for the life of the thermostat, whereas for
`Settings and adjustments, the operator interface may be used
`periodically and should be as user friendly as possible. In the
`past, the installer configuration proceSS was very obscure
`and error prone Since it had been a Secondary function of the
`operator user interface that partially reused Some of the
`operator interface features in an obscure Secondary manner
`So as to attempt reducing costs associated with the device.
`This approach was time consuming and error prone, had to
`be repeated for each installation, and was still costly.
`0011. By removing the thermostat configuration installer
`interface from the thermostat operator interface to a PDA, as
`in the air management System, the following benefits are
`noted. There is an easy to use configuration process with
`context checking on previous Selections So only valid
`options are presented and errors cannot be made, and also
`easy to use navigation of thermostat configuration Screens.
`
`Novice users may be directed to the next appropriate param
`eter entry Screen based on the context of previous configu
`ration Selections. Configurations can be done ahead of time
`and downloaded quickly at installation time. Similar con
`figurations do not have to be repeated on every device but
`simply recalled from storage and downloaded. The PDA
`based thermostat configuration application may generate a
`code that represents the raw configuration. This code can be
`recorded (for example on paper) and entered by hand
`quickly into the thermostat keyboard if a PDA is not
`available at the job Site. There is context dependent control
`loop tuning. The thermostat PID (viz., proportional, integral
`and derivative gains) control loop tuning parameters may be
`automatically adjusted as a function of equipment type,
`number of output stages, output type (modulating or dis
`crete), the HVAC process, and other factors as desired.
`0012 APDA and its interfacing with the thermostat of an
`air management System may also be used for automatic
`testing, checkout, analysis and diagnosis of the System.
`Testing and trouble-shooting a complex fully featured com
`mercial thermostat may be time consuming and confusing
`Since the configuration must first be understood and then the
`operation must be run through valid modes with inputs and
`Set points temporarily manipulated, plus waiting for the
`delays built into the controller, to Verify operation.
`0013 Commissioning a complex fully featured commer
`cial thermostat also may be time consuming and confusing.
`The thermostat configuration should first be understood and
`then the commissioning process may be run through valid
`operational modes with inputs and Set points temporarily
`manipulated while waiting for the delays built into the
`controller to Verify operation.
`0014. The PDA based online diagnostics may automati
`cally discover the thermostat configuration, turn off normal
`controller delays, temporarily override Sensor inputs and Set
`points, Verify proper output action including monitoring the
`discharge air temperature for the resulting temperature
`behavior based on the equipment Stages activated. Problems
`discovered may be reported, automatically recorded and the
`original operating parameters may be restored. This means
`that leSS expertise may be required by the technicians Sent to
`install and trouble shoot thermostat installations.
`0015. A thermostat may be designed to interface to a
`PDA or other handy low cost device with an easy wire, IR
`or RF connection that will allow it do fast, accurate auto
`matic thermost at testing, diagnosing and trouble-shooting.
`The PDA may automatically obtain the thermostat configu
`ration, turn off normal controller delays, temporarily over
`ride Sensor inputs and Set points, and verify proper output
`action including monitoring the entry and discharge air
`temperatures for the resulting temperature behavior based on
`the equipment Stages activated. Problems discovered can be
`reported, automatically recorded and the original operating
`parameters can be restored. This means that leSS expertise is
`required by the technicians Sent to install and trouble Shoot
`thermostats. Smart Status reporting Simplifies the thermostat
`installers' field-commissioning task of Selecting and moni
`toring the appropriate real time data. The Smart Status report
`content and layout may be based on a theme of management
`by exclusion. The report generator may respond to real time
`parameter and data changes in the thermostat environment.
`There may be a possible web-based system in which the
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`
`installer or technician need not to go out to the site of the air
`management System. The installer or technician may be able
`to diagnose and can fix the System over the internet, Ethernet
`or the like. However, using the PDA and its infrared inter
`face may be as or more reasonable than the configuring or
`diagnosing a thermostat, its Sub-base and corresponding air
`management System. PDA configuring and diagnostics may
`be utilized in residential homes as well as commercial
`facilities.
`0016 Programmable commercial thermostat systems
`have also been gaining in popularity due to the energy
`Savings associated with programmable Schedules and Set
`points. Most Small commercial buildings with one or two
`Zones typically may have rooftop equipment controlled
`through relay contacts Such as heat Stage 1, heat Stage 2,
`cooling Stage 1, cooling Stage 2, and fan. These controls may
`be interfaced through rem