Efficient fan controller
View Patent ↗An efficient fan controller for Heating Ventilating Air Conditioning (HVAC) systems including at least one electrical signal input from thermostat or equipment control terminals with a microprocessor to control a switching device connected to a signal output to control a fan relay and operate a system fan. The microprocessor is configured to monitor a thermostat call for cooling/heating duration and determine a variable fan-off delay based on the cooling cycle or 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 can include a heat pump detection signal input and electrical signal inputs to connect to a thermostat heat terminal, heat pump reversing valve terminal, or compressor terminal. The fan controller can also include a normally-closed relay connected to the switching device to maintain continuity between the fan signal input and output.
1. A fan controller ( 211 ) for a Heating Ventilation Air Conditioning (HVAC) system ( 100 ), the fan controller comprising:
a microprocessor ( 304 );
at least one electrical input configured to receive an electrical signal from a thermostat or equipment control terminal ( 201 ), wherein the electrical input is selected from the group consisting of:
1) a fan signal input ( 214 ) configured to connect to a thermostat G signal terminal ( 204 ) for the microprocessor ( 304 ) to monitor for an active G signal,
2) an Air Conditioning (AC) signal input ( 215 ) configured to connect to a thermostat Y signal terminal ( 207 ) for the microprocessor ( 304 ) to monitor for an active Y signal, and
3) a heat signal input ( 216 ), configured to connect to a thermostat W signal terminal ( 208 ) for the microprocessor ( 304 ) to monitor for an active W signal;
a switching device ( 301 ) electrically connected to the microprocessor ( 304 ) to receive a control signal from the microprocessor ( 304 );
a fan relay signal output ( 212 ) from the switching device ( 301 ); and
wherein the microprocessor ( 304 ) is configured to perform at least one action selected from the group consisting of:
monitor a duration of a cooling cycle and determine a variable fan-off delay time based on the duration of the cooling cycle, and at an end of the cooling cycle, either energize or continue to energize the fan relay signal output ( 212 ) to operate a system fan ( 206 ) for the variable fan-off delay time to deliver additional cooling energy to a conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency, and
monitor a duration of a heating cycle and determine the variable fan-off delay time based on the duration of the heating cycle, and at an end of a heating cycle, either energize or continue to energize the fan relay signal output ( 212 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
2. The fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to determine at least one duration selected from the group consisting of:
the duration of the cooling cycle is based on monitoring at least one time period selected from the group consisting of:
an active G signal duration with an inactive W signal,
an active Y signal duration with the inactive W signal,
the active G signal duration with the active Y signal and the inactive W signal, and
a time period from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling; and
the duration of the heating cycle is based on monitoring at least one time period selected from the group consisting of:
an active W signal duration with an inactive G signal or an inactive Y signal,
the active W signal duration with the active G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal, and
a time period from when the thermostat initiates a call for heating until the thermostat terminates the call for heating.
3. A fan controller ( 211 ) of claim 1 , wherein the fan controller is configured to receive power from at least one power source selected from the group consisting of:
a system transformer ( 210 ), an AC-DC converter ( 303 ), and a battery ( 306 ).
4. A fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to determine the variable fan-off delay time based on the duration of the cooling cycle, and at the end of the cooling cycle either energize or continue to energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to the fan relay signal output ( 212 ) and the fan relay ( 205 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional cooling energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
5. The fan controller ( 211 ) of claim 4 , wherein the duration of the cooling cycle is based on monitoring at least one time period selected from the group consisting of:
an active G signal duration with an inactive W signal,
an active Y signal duration with the inactive W signal,
the active G signal duration with the active Y signal and the inactive W signal,
a time period from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling.
6. A fan controller ( 211 ) of claim 1 , wherein:
the microprocessor ( 304 ) is configured to determine the variable fan-off delay time based on the duration of the heating cycle; and
at the end of the heating cycle, either energize or continue to energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to the fan relay signal output ( 212 ) and the fan relay ( 205 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
7. The fan controller ( 211 ) of claim 6 , wherein the thermostat call for heating is based on monitoring at least one time period selected from the group consisting of:
an active W signal duration with an inactive G signal or an inactive Y signal;
the active W signal duration with the active G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal, and a time period from when the thermostat initiates a call for heating until the thermostat terminates the call for heating.
8. The fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to detect on the signal inputs a signal input state selected from the group consisting of:
a zero signal,
an active signal, and
an inactive signal or a floating signal.
9. The fan controller ( 211 ) of claim 1 , wherein the switching device ( 301 ) is electrically connected to the microprocessor ( 304 ) to receive the control signal from the microprocessor ( 304 ), and the fan controller ( 211 ) further includes a normally-closed relay ( 309 ) electrically connected to the switching device ( 301 ) to maintain continuity between the fan signal input 214 and the fan signal output 212 in an event of a failure of the fan controller.
10. The fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for cooling is active based on the active G signal or the active Y signal and an inactive W signal;
energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to energize the fan controller fan relay signal output ( 212 ) to energize the fan relay ( 205 ) and operate the system fan ( 206 ) while the thermostat call for cooling is active;
determine the duration of the cooling cycle based on an active G signal duration or an active Y signal duration; and
operate or continue to operate the system fan ( 206 ) at the end of the cooling cycle for a variable fan-off delay time based on the duration of the cooling cycle to deliver additional cooling energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
11. The fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for heating is active based on the active W signal and an inactive G signal and an inactive Y signal;
energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to energize the fan controller fan relay signal output ( 212 ) to energize the fan relay ( 205 ) and operate the system fan ( 206 ) while the thermostat call for heating is active;
determine the duration of the heating cycle based on an active W signal duration; and
operate or continue to operate the system fan ( 206 ) at the end of the heating cycle for the variable fan-off delay time based on the duration of the heating cycle to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
12. The fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for heating is active based on the active W signal and an inactive G signal and an inactive Y signal;
monitor the duration of the heating cycle based on an active W signal duration;
perform at least one action selected from the group consisting of:
energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through a heating system,
wait while the active W signal is present and the heating system controls the system fan ( 206 ) to circulate air through the heating system, and
wait for a first time period while the heating system controls the system fan ( 206 ) to circulate air through the heating system and after a first time period with the system fan ( 206 ) operating, energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through the heating system;
after the active W signal is no longer detected, set the duration of the heating cycle to the active W signal duration;
compute the variable fan-off delay time as a function of the duration of the heating cycle;
energize or continue to energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through the heating system for the entire variable fan-off delay time, and de-energize the switching device ( 301 ) connected to the fan relay ( 205 ) at the end of the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
13. The fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for heating is active based on the active W signal and an inactive G signal and an inactive Y signal;
if the thermostat call for heating is active, then monitor the active W signal duration to determine the duration of the heating cycle;
perform at least one action selected from the group consisting of:
energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 );
allow the heating system to control the system fan ( 206 ) and
after a first period of time energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 ) at a higher speed compared to when the fan controller fan relay signal output ( 212 ) is not energized and the system fan ( 206 ) is controlled by the heating system;
after the active W signal is no longer detected, determine the variable fan-off delay time based on the duration of the heating cycle; and
energize or continue to energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 ) for the variable fan-off delay time after the heating cycle has ended to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
14. The fan controller ( 211 ) of claim 1 , wherein the microprocessor ( 304 ) is configured to perform at least one action selected from the group consisting of:
close an economizer damper after the cooling cycle has ended and throughout the variable fan-off delay time,
adjust the economizer damper to a minimum position after the cooling cycle has ended and throughout the variable fan-off delay time and close the economizer damper at the end of the variable fan-off delay time,
close the economizer damper after the heating cycle has ended and throughout the variable fan-off delay time, and
adjust the economizer damper to the minimum position after the heating cycle has ended and throughout the variable fan-off delay time and close the economizer damper at the end of the variable fan-off delay time.
15. A fan controller ( 211 ) for a Heating Ventilation Air Conditioning (HVAC) system ( 100 ), the fan controller comprising:
a microprocessor ( 304 );
at least one electrical input configured to receive an electrical signal from a thermostat or equipment control terminal ( 201 ), wherein the electrical input is selected from the group consisting of:
1) a fan signal input ( 214 ) configured to connect to a thermostat G signal terminal ( 204 ) for the microprocessor ( 304 ) to monitor for an active G signal,
2) an Air Conditioning (AC) signal input ( 215 ) configured to connect to a thermostat Y signal terminal ( 207 ) for the microprocessor ( 304 ) to monitor for an active Y signal,
3) a heat signal input ( 216 ), configured to connect to at least one thermostat terminal selected from the group consisting of:
a thermostat W heat terminal ( 208 ) for the microprocessor ( 304 ) to monitor for an active W signal;
a thermostat O Heat Pump (HP) reversing valve terminal ( 235 ) for the microprocessor ( 304 ) to monitor for an active O signal, and
a thermostat BR heat pump reversing valve terminal ( 236 ) for the microprocessor ( 304 ) to monitor for an active BR signal;
4) an HP Detection (HPD) signal input ( 234 ) configured to connect to a 24 VAC Hot signal ( 210 b ) from a system transformer ( 210 ) using at least one connection selected from the group consisting of:
a wire with a diode ( 275 ) for the microprocessor ( 304 ) to monitor for an active rectified HPD ( 234 ) signal, and
a wire ( 265 ) without the diode for the microprocessor ( 304 ) to monitor for an active sinusoidal HPD ( 234 ) signal;
a switching device ( 301 ) electrically connected to the microprocessor ( 304 ) to receive a control signal from the microprocessor ( 304 );
a fan relay signal output ( 212 ) from the switching device ( 301 ); and
wherein the microprocessor ( 304 ) is configured to perform at least one action selected from the group consisting of:
monitor a thermostat call for cooling duration and determine a variable fan-off delay time based on the thermostat call for cooling duration, and at an end of a cooling cycle, either energize or continue to energize the fan relay signal output ( 212 ) to operate a system fan ( 206 ) for the variable fan-off delay time to deliver additional cooling energy to a conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency, and
monitor a thermostat call for heating duration and determine the variable fan-off delay time based on the thermostat call for heating duration, and at an end of a heating cycle, either energize or continue to energize the fan relay signal output ( 212 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
16. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to determine at least one duration selected from the group consisting of:
the thermostat call for cooling duration based on monitoring at least one time period selected from the group consisting of:
an active G signal duration with an inactive W signal,
an active Y signal duration with the inactive W signal,
the active G signal duration with the active Y signal and the inactive W signal,
the active G signal duration with the inactive W signal with the active rectified HPD signal,
the active G signal duration with the active W signal with the active sinusoidal HPD signal,
the active Y signal duration with the inactive W signal with the active rectified HPD signal,
the active Y signal duration with the active W signal with the active sinusoidal HPD signal, and
a time period from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling; and
the thermostat call for heating duration based on monitoring at least one time period selected from the group consisting of:
an active W signal duration with an inactive G signal or an inactive Y signal,
the active W signal duration with the active G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal,
the active G signal duration with the inactive W signal with the active sinusoidal HPD signal,
the active G signal duration with the active W signal with the active rectified HPD signal,
the active Y signal duration with the inactive W signal with the active sinusoidal HPD signal,
the active Y signal duration with the active W signal with the active rectified HPD signal, and
a time period from when the thermostat initiates a call for heating until the thermostat terminates the call for heating.
17. A fan controller ( 211 ) of claim 15 , wherein the fan controller is configured to receive power from at least one power source selected from the group consisting of: the system transformer ( 210 ), an AC-DC converter ( 303 ), a battery ( 306 ), and a super capacitor ( 312 ).
18. A fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to determine the variable fan-off delay time based on the thermostat call for cooling duration, and at the end of the cooling cycle, either energize or continue to energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to the fan relay signal output ( 212 ) and the fan relay ( 205 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional cooling energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
19. The fan controller ( 211 ) of claim 18 , wherein the thermostat call for cooling duration is based on monitoring at least one time period selected from the group consisting of:
the active G signal duration with an inactive W signal,
an active Y signal duration with the inactive W signal,
the active G signal duration with the active Y signal and the inactive W signal,
the active G signal duration with the inactive W signal with the active rectified HPD signal,
the active G signal duration with the active W signal with the active sinusoidal HPD signal,
the active Y signal duration with the inactive W signal with the active rectified HPD signal,
the active Y signal duration with the active W signal with the active sinusoidal HPD signal, and
a time period from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling.
20. A fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to determine the variable fan-off delay time based on the thermostat call for heating duration, and at the end of the heating cycle, either energize or continue to energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to the fan relay signal output ( 212 ) and the fan relay ( 205 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
21. The fan controller ( 211 ) of claim 20 , wherein the thermostat call for heating duration is based on monitoring at least one time period selected from the group consisting of:
an active W signal duration with an inactive G signal or an inactive Y signal;
the active W signal duration with the active G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal,
the active G signal duration with an inactive W signal with the active sinusoidal HPD signal,
the active G signal duration with the active W signal with the active rectified HPD signal,
the active Y signal duration with the inactive W signal with the active sinusoidal HPD signal,
the active Y signal duration with the active W signal with the active rectified HPD signal, and
a time period from when the thermostat initiates a call for heating until the thermostat terminates the call for heating.
22. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to detect on the signal inputs, a signal input state selected from the group consisting of:
a zero signal,
the active sinusoidal signal,
the rectified signal, and
an inactive or a floating signal.
23. The fan controller ( 211 ) of claim 15 , wherein the switching device ( 301 ) is electrically connected to the microprocessor ( 304 ) to receive the control signal from the microprocessor ( 304 ), and the fan controller ( 211 ) further includes a normally-closed relay ( 309 ) electrically connected to the switching device ( 301 ) to maintain continuity between the fan signal input ( 214 ) and the fan signal output ( 212 ) in an event of a failure of the fan controller.
24. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for cooling is active based on monitoring at least one signal combination selected from the group consisting of:
the active G signal with an inactive W signal,
the active Y signal with the inactive W signal,
the active G signal with the active Y signal and the inactive W signal,
the active G signal with the inactive W signal with the active rectified HPD signal,
the active G signal with the active W signal with the active sinusoidal HPD signal,
the active Y signal with the inactive W signal with the active rectified HPD signal, and
the active Y signal with the active W signal with the active sinusoidal HPD signal;
energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to energize the fan controller fan relay signal output ( 212 ) to energize the fan relay ( 205 ) and operate the system fan ( 206 ) while the thermostat call for cooling is active;
determine the thermostat call for cooling duration based on at least one duration selected from a group consisting of:
an active G signal duration with the inactive W signal,
an active Y signal duration with the inactive W signal,
the active G signal duration with the active Y signal and the inactive W signal,
the active G signal duration with the inactive W signal with the active rectified HPD signal,
the active G signal duration with the active W signal with the active sinusoidal HPD signal,
the active Y signal duration with the inactive W signal with the active rectified HPD signal,
the active Y signal duration with the active W signal with the active sinusoidal HPD signal, and
a time period from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling; and
determine the variable fan-off delay time based on the thermostat call for cooling duration, and at the end of the cooling cycle, operate or continue to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional cooling energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
25. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for heating is active based on monitoring at least one signal combination selected from the group consisting of:
the active W signal with an inactive G signal or an inactive Y signal,
the active W signal with the active G signal and the inactive Y signal,
the active W signal with the active G signal and the active Y signal,
the active G signal with an inactive W signal with the active sinusoidal HPD signal,
the active G signal with the active W signal with the active rectified HPD signal,
the active Y signal with the inactive W signal with the active sinusoidal HPD signal, and
the active Y signal duration with the active W signal with the active rectified HPD signal;
energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to energize the fan controller fan relay signal output ( 212 ) to energize the fan relay ( 205 ) and operate the system fan ( 206 ) while the thermostat call for heating is active;
determine the thermostat call for heating duration based at least one duration selected from a group consisting of:
an active W signal duration with the inactive G signal or the inactive Y signal;
the active W signal duration with the active G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal,
an active G signal duration with the inactive W signal with the active sinusoidal HPD signal,
the active G signal duration with the active W signal with the active rectified HPD signal,
the active Y signal duration with the inactive W signal with the active sinusoidal HPD signal,
the active Y signal duration with the active W signal with the active rectified HPD signal, and
the thermostat call for heating duration defined from when the thermostat initiates a call for heating until the thermostat terminates the call for heating; and
determine the variable fan-off delay time based on the thermostat call for heating duration, and at the end of the heating cycle operate or continue to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
26. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for heating is active based on monitoring at least one signal combination selected from the group consisting of:
the active W signal with an inactive G signal or an inactive Y signal;
the active W signal with the active G signal and the inactive Y signal,
the active W signal with the active G signal and the active Y signal,
the active G signal with an inactive W signal with the active sinusoidal HPD signal,
the active G signal with the active W signal with the active rectified HPD signal,
the active Y signal with the inactive W signal with the active sinusoidal HPD signal, and
the active Y signal duration with the active W signal with the active rectified HPD signal;
monitor and store the thermostat call for heating duration based at least one duration selected from a group consisting of:
an active W signal duration with the inactive G signal or the inactive Y signal;
the active W signal duration with the active G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal,
an active G signal duration with an inactive W signal with the active sinusoidal HPD signal,
the active G signal duration with the active W signal with the active rectified HPD signal,
the active Y signal duration with the inactive W signal with the active sinusoidal HPD signal,
the active Y signal duration with the active W signal with the active rectified HPD signal, and
a time period from when the thermostat initiates a call for heating until the thermostat terminates the call for heating; and
perform at least one action selected from the group consisting of:
energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through a heating system,
wait while the thermostat call for heating is active and the heating system controls the system fan ( 206 ) to circulate air through the heating system, and
wait for a first time period while the heating system controls the system fan ( 206 ) to circulate air through the heating system and after a first time period with the system fan ( 206 ) operating, energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through the heating system; and
after the active W signal is no longer detected, compute the variable fan-off delay time as a function of the thermostat call for heating duration;
energize or continue to energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through the heating system for the entire variable fan-off delay time, and de-energize the switching device ( 301 ) connected to the fan relay ( 205 ) at the end of the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
27. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to:
determine if the thermostat call for heating is active based on monitoring at least one signal combination selected from the group consisting of:
the active W signal with an inactive G signal or an inactive Y signal;
the active W signal with the active G signal and the inactive Y signal,
the active W signal with the active G signal and the active Y signal,
the active G signal with an inactive W signal with the active sinusoidal HPD signal,
the active G signal with the active W signal with the active rectified HPD signal,
the active Y signal with the inactive W signal with the active sinusoidal HPD signal, and
the active Y signal duration with the active W signal with the active rectified HPD signal; and
determine the thermostat call for heating duration if the thermostat call for heating is active, based at least one duration selected from a group consisting of:
an active W signal duration with the inactive G signal or the inactive Y signal;
the active W signal duration with the active G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal,
an active G signal duration with an inactive W signal with the active sinusoidal HPD signal,
the active G signal duration with the active W signal with the active rectified HPD signal,
the active Y signal duration with the inactive W signal with the active sinusoidal HPD signal,
the active Y signal duration with the active W signal with the active rectified HPD signal, and
a time period from when the thermostat initiates a call for heating until the thermostat terminates the call for heating; and
perform at least one action selected from the group consisting of:
energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 ),
allow the heating system to control the system fan ( 206 ), and
after a first period of time, energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 ) at a higher speed compared to when the fan controller fan relay signal output ( 212 ) is not energized and the system fan ( 206 ) is controlled by the heating system;
after thermostat call for heating is inactive, determine a variable fan-off delay time based on the thermostat call for heating duration; and
energize or continue to energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 ) for the variable fan-off delay time after the heating cycle has ended to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
28. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to perform at least one action selected from the group consisting of:
close an economizer damper after the cooling cycle has ended and throughout the variable fan-off delay time,
adjust the economizer damper to a minimum position after the cooling cycle has ended and throughout the variable fan-off delay time and close the economizer damper at the end of the variable fan-off delay time,
close the economizer damper after the heating cycle has ended and throughout the variable fan-off delay time, and
adjust the economizer damper to the minimum position after the heating cycle has ended and throughout the variable fan-off delay time and close the economizer damper at the end of the variable fan-off delay time.
29. The fan controller ( 211 ) of claim 15 , wherein the microprocessor ( 304 ) is configured to determine a system type and cooling or heating mode based on signals present on the HVAC thermostat or equipment terminals ( 201 ) for at least one system type selected from the group consisting of:
a direct expansion air conditioning system operating in cooling mode,
a heat pump system operating in cooling mode,
a hydronic coil system operating in cooling mode,
a gas furnace system operating in heating mode,
the heat pump system operating in heating mode,
the hydronic coil system operating in heating mode, and
an electric resistance system operating in heating mode.
30. The fan controller ( 211 ) of claim 15 , wherein the switching device ( 301 ) is electrically connected to the microprocessor ( 304 ) to receive a control signal from the microprocessor ( 304 ), and further including a normally-closed relay ( 309 ) electrically connected to the switching device ( 301 ) to maintain continuity between the fan signal input ( 214 ) and the fan signal output ( 212 ) in the event of a failure of the fan controller.
31. A fan controller ( 211 ) for a Heating Ventilation Air Conditioning (HVAC) system ( 100 ), the fan controller comprising:
a microprocessor ( 304 );
at least one electrical input configured to receive an electrical signal from a thermostat or equipment control terminal ( 201 ), wherein the electrical input is selected from the group consisting of:
1) a fan signal input ( 214 ) configured to connect to a thermostat G signal terminal ( 204 ) for the microprocessor ( 304 ) to monitor for an active G signal,
2) an Air Conditioning (AC) signal input ( 215 ) configured to connect to a thermostat Y signal terminal ( 207 ) for the microprocessor ( 304 ) to monitor for an active Y signal, and
3) a heat signal input ( 216 ), configured to connect to a thermostat W signal terminal ( 208 ) for the microprocessor ( 304 ) to monitor for an active W signal;
a switching device ( 301 ) electrically connected to the microprocessor ( 304 ) to receive a control signal from the microprocessor ( 304 );
a fan relay signal output ( 212 ) from the switching device ( 301 ); and
wherein the microprocessor ( 304 ) is 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 after the thermostat terminates a call for cooling, either energize or continue to energize the fan relay signal output ( 212 ) to operate a system fan ( 206 ) for the variable fan-off delay time to deliver additional cooling energy to a conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency, and
monitor a heating cycle duration and determine a variable fan-off delay time based on the heating cycle duration, and at an end of a heating cycle, either energize or continue to energize the fan relay signal output ( 212 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
32. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to determine at least one cooling cycle duration selected from the group consisting of:
a cooling on time defined from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling, and
a cooling off time defined from when the thermostat terminates the call for cooling until the thermostat initiates the call for cooling plus the cooling on time.
33. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to determine at least one heating cycle duration selected from the group consisting of:
a heating on time defined from when the thermostat initiates a call for heating until the thermostat terminates the call for heating, and
a heating off time defined from when the thermostat terminates the call for heating until the thermostat initiates the call for heating plus the heating on time.
34. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to determine at least one duration selected from the group consisting of:
the cooling cycle duration based on at least one time period selected from the group consisting of:
an active G signal duration with an inactive W signal,
an inactive G signal duration with the inactive W signal,
the active Y signal duration with the inactive W signal,
an inactive Y signal duration with the inactive W signal,
the active G signal duration with the active Y signal and the inactive W signal,
the inactive G signal duration with the inactive Y signal and the inactive W signal,
a cooling on time from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling, and
the cooling off time defined from when the thermostat terminates the call for cooling until the thermostat initiates the call for cooling plus the cooling on time; and
the heating cycle duration based on at least one time period selected from the group consisting of:
an active W signal duration with an inactive G signal or an inactive Y signal,
an inactive W signal duration with the inactive G signal or the inactive Y signal,
the active W signal duration with the active G signal and the inactive Y signal,
the inactive W signal duration with the inactive G signal and the inactive Y signal,
the active W signal duration with the active G signal and the inactive Y signal,
the inactive W signal duration with the inactive G signal and the inactive Y signal,
a heating on time from when the thermostat initiates a call for heating until the thermostat terminates the call for heating, and
the heating off time defined from when the thermostat terminates the call for heating until the thermostat initiates the call for heating plus the heating on time.
35. A fan controller ( 211 ) of claim 31 , wherein the fan controller is configured to receive power from at least one power source selected from the group consisting of: a system transformer ( 210 ), an AC-DC converter ( 303 ), and a battery ( 306 ).
36. A fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to determine the variable fan-off delay time based on the cooling cycle duration, and at the end of the cooling cycle, either energize or continue to energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to the fan relay signal output ( 212 ) and the fan relay ( 205 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional cooling energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
37. The fan controller ( 211 ) of claim 36 , wherein the cooling cycle duration is based on at least one time period selected from the group consisting of:
an active G signal duration with an inactive W signal,
an inactive G signal duration with the inactive W signal,
an active Y signal duration with the inactive W signal,
an inactive Y signal duration with the inactive W signal,
the active G signal duration with the active Y signal and the inactive W signal,
the inactive G signal duration with an inactive Y signal and the inactive W signal,
a cooling on time from when the thermostat initiates a call for cooling until the thermostat terminates the call for cooling, and
a cooling off time defined from when the thermostat terminates the call for cooling until the thermostat initiates the call for cooling plus the cooling on time.
38. A fan controller ( 211 ) of claim 31 , wherein:
the microprocessor ( 304 ) is configured to determine the variable fan-off delay time based on the heating cycle duration; and
at the end of the heating cycle, either energize or continue to energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to the fan relay signal output ( 212 ) and the fan relay ( 205 ) to operate the system fan ( 206 ) for the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
39. The fan controller ( 211 ) of claim 38 , wherein the heating cycle duration is based on at least one time period selected from the group consisting of:
an active W signal duration with an inactive G signal or an inactive Y signal,
an inactive W signal duration with the inactive G signal or the inactive Y signal,
the active W signal duration with the active G signal and the inactive Y signal,
the inactive W signal duration with the inactive G signal and the inactive Y signal,
the active W signal duration with the active G signal and the active Y signal,
a heating on time from when the thermostat initiates a call for heating until the thermostat terminates the call for heating, and
a heating off time defined from when the thermostat terminates the call for heating until the thermostat initiates the call for heating plus the heating on time.
40. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to detect on the signal inputs, a signal input state selected from the group consisting of:
a zero signal,
an active signal, and
an inactive or floating signal.
41. The fan controller ( 211 ) of claim 31 , wherein:
the switching device ( 301 ) is electrically connected to the microprocessor ( 304 ) to receive the control signal from the microprocessor ( 304 ); and
the fan controller ( 211 ) further includes a normally-closed relay ( 309 ) electrically connected to the switching device ( 301 ) to maintain continuity between the fan signal input 214 and the fan signal output 212 in an event of a failure of the fan controller.
42. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to:
determine if the cooling cycle is inactive based on an inactive G signal or an inactive Y signal, and if the cooling cycle is inactive, then determine an inactive cooling cycle duration based on an inactive G signal duration or an inactive Y signal duration;
determine if the cooling cycle is active based on the active G signal or the active Y signal and an inactive W signal, and if the cooling cycle is active, and then energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to energize the fan controller fan relay signal output ( 212 ) to energize the fan relay ( 205 ) and operate the system fan ( 206 ) while the cooling cycle is active;
determine the cooling cycle duration based on the active G signal duration, or the active Y signal duration, or the inactive G signal duration plus the active G signal duration, or an inactive Y signal duration plus the active Y signal duration; and
operate or continue to operate the system fan ( 206 ) at the end of the cooling cycle for a variable fan-off delay time based on the cooling cycle duration to deliver additional cooling energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
43. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to:
determine if the heating cycle is inactive based on an inactive W signal, and if the heating cycle is inactive, then determine an inactive heating cycle duration based on an inactive W signal duration;
determine if the heating cycle is active based on the active W signal and an inactive G signal and an inactive Y signal, and if the heating cycle is active, then energize the control signal from the microprocessor ( 304 ) to the switching device ( 301 ) to energize the fan controller fan relay signal output ( 212 ) to energize the fan relay ( 205 ) and operate the system fan ( 206 ) while the heating cycle is active;
determine the heating cycle duration based on the active W signal duration, or the inactive W signal duration plus the active W signal duration; and
operate or continue to operate the system fan ( 206 ) at the end of the heating cycle for a variable fan-off delay time based on the heating cycle duration to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
44. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to:
determine if the heating cycle is inactive based on an inactive W signal, and if the heating cycle is inactive, then determine an inactive heating cycle duration based on an inactive W signal duration;
determine if the heating cycle is active based on the active W signal and an inactive G signal and an inactive Y signal, and if the heating cycle is active, then perform at least one action selected from the group consisting of:
energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through a heating system,
wait while the active W signal is present and the heating system controls the system fan ( 206 ) to circulate air through the heating system, and
wait for a first time period while the heating system controls the system fan ( 206 ) to circulate air through the heating system, and after a first time period with the system fan ( 206 ) operating, energize the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through the heating system;
after the active W signal is no longer detected, determine the heating cycle duration based on the active W signal duration, or the sum of the inactive W signal duration plus the active W signal duration;
compute the variable fan-off delay time as a function of the heating cycle duration; and
energize, or continue to energize, the switching device ( 301 ) connected to the fan relay ( 205 ) to operate the system fan ( 206 ) to circulate air through the heating system for the entire variable fan-off delay time; and
de-energize the switching device ( 301 ) connected to the fan relay ( 205 ) at the end of the variable fan-off delay time to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
45. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to:
determine if the heating cycle is inactive based on an inactive W signal and an inactive G signal and an inactive Y signal, and if the heating cycle is inactive, then determine an inactive heating cycle duration based on an inactive W signal duration;
determine if the heating cycle is active based on the active W signal and the inactive G signal and the inactive Y signal, and if the heating cycle is active, then perform at least one action selected from the group consisting of:
energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 );
allow a heating system to control the system fan ( 206 ), and
after a first period of time, energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 ) at a higher speed compared to when the fan controller fan relay signal output ( 212 ) is not energized and the system fan ( 206 ) is controlled by the heating system;
after the active W signal is no longer detected, determine the heating cycle duration based on an active W signal duration, or the sum of the inactive W signal duration plus the active W signal duration;
determine a variable fan-off delay time based on the heating cycle duration; and
energize or continue to energize the fan controller fan relay signal output ( 212 ) to operate a system fan ( 206 ) for the variable fan-off delay time after the heating cycle has ended to deliver additional heating energy to the conditioned space wherein the variable fan-off delay time is determined in order to improve energy efficiency.
46. The fan controller ( 211 ) of claim 31 , wherein the microprocessor ( 304 ) is configured to perform at least one action selected from the group consisting of:
close an economizer damper after the cooling cycle has ended and throughout the variable fan-off delay time,
adjust the economizer damper to a minimum position after the cooling cycle has ended and throughout the variable fan-off delay time and close the economizer damper at the end of the variable fan-off delay time,
close the economizer damper after the heating cycle has ended and throughout the variable fan-off delay time, and
adjust the economizer damper to the minimum position after the heating cycle has ended and throughout the variable fan-off delay time and close the economizer damper at the end of the variable fan-off delay time.