US5438844A — Microprocessor-based controller

Claim 1

Independent Claim 135 words

In a gas heat pump system having a variable speed compressor, a controller comprising: variable capacity control means for responding to at least one thermostat output signal and based upon each thermostat output signal computing in real-time performance parameters at variable capacity heating/cooling load conditions of the gas heat pump system; defrost control means for calculating a maximum heat pump operating time period between successive defrost cycles and a minimum heat pump operating time period of each said defrost cycle during a heating mode of the gas heat pump system as a function of a sensed time, a temperature, and variable capacity operating conditions calculated by said variable capacity control means; and said controller communicating with at least one component of said gas heat pump system for overall control of said gas heat pump system.

Claim 2

Dependent Claim 135 words

In a gas heat pump system having a variable speed compressor, a controller comprising: variable capacity control means for responding to at least one thermostat output signal and based upon each thermostat output signal computing in real-time performance parameters at variable capacity heating/cooling load conditions of the gas heat pump system; defrost control means for calculating a maximum heat pump operating time period between successive defrost cycles and a minimum heat pump operating time period of each said defrost cycle during a heating mode of the gas heat pump system as a function of a sensed time, a temperature, and variable capacity operating conditions calculated by said variable capacity control means; and said controller communicating with at least one component of said gas heat pump system for overall control of said gas heat pump system.

Claim 3

Dependent Claim 77 words

A controller according to claim 1 further comprising computing means for determining a current operational state of the gas heat pump system and based upon current sensed values of said current operational state calculating necessary conditions for a successive operational state and emitting at least one of a sensor input value, a control output value, and an internal software variable value from said computing means for transitioning the gas heat pump system to said successive operational state.

Claim 4

Dependent Claim 44 words

A controller according to claim 2 wherein said computing means comprise a plurality of said output signals, and at least one programmed algorithm that determines a controlled sequence of said output signals to achieve a desired operating efficiency for the gas heat pump system.

Claim 5

Dependent Claim 39 words

A controller according to claim 2 wherein said necessary conditions for said successive operational state are calculated as a function of at least one of a sensor input value, a control output value and an internal software variable value.

Claim 6

Dependent Claim 71 words

A controller according to claim 1 further comprising manual mode control means for operating the gas heat pump system at a first control level wherein each said actuator is individually controlled, and for operating the gas heat pump system at a second control level wherein said manual mode control means generate at least one substitute signal otherwise generated by a thermostat during an operating mode of the gas heat pump system.

Claim 7

Dependent Claim 75 words

A controller according to claim 1 further comprising manual mode control means for verifying correct operation of at least one actuator of the gas heat pump system as a function of a sequenced input signal while the gas heat pump system is in a standby mode, and for computing and generating an output signal for controlling each said actuator to achieve efficient operation control of the gas heat pump system based upon predetermined operating parameters.

Claim 8

Dependent Claim 26 words

A controller according to claim 1 wherein said variable capacity control means respond to each said thermostat output signal and a plurality of sensor input signals.

Claim 9

Dependent Claim 35 words

A controller according to claim 7 wherein said sensor input signals correspond to at least one of an outdoor air temperature, a liquid line temperature, an engine coolant temperature and an indoor air discharge temperature.

Claim 10

Dependent Claim 24 words

A controller according to claim 1 wherein said temperature corresponds to at least one of a liquid line temperature and an outdoor air temperature.

Claim 11

Dependent Claim 39 words

A controller according to claim 1 wherein said defrost control means integrates sensed compressor speed, outdoor air temperature and delivered heating capacity of the gas heat pump system over time to determine said maximum heat pump operating time period.

Claim 12

Dependent Claim 70 words

A controller according to claim 1 wherein an output of the controller controls at least one of an engine on/off output, an engine speed output, an outdoor fan on/off output, an outdoor fan speed output, an auxiliary heat output, a reversing valve output, a coolant valve output, an indoor blower enable output, and an indoor blower speed output, depending upon an output voltage value from said output of the controller.

Claim 13

Dependent Claim 42 words

A controller according to claim 1 further comprising reset means for resetting the controller when one of a supply voltage to said controller falls below a predetermined minimum supply voltage value and the controller enters at least one incorrect state of operation.

Claim 14

Dependent Claim 44 words

A controller according to claim 1 further comprising a communications interface with which the controller receives and transmits messages via a plurality of current drive signals with an engine control system and a service analyzer which are multiplexed to communicate through a common circuit.

Claim 15

Dependent Claim 24 words

A controller according to claim 13 wherein said communication interface commands an engine of the gas heat pump system to exercise variable capacity control.

Claim 16

Dependent Claim 47 words

A controller according to claim 1 further comprising information means for storing historical data related to the gas heat pump system and storing diagnostic data in a non-volatile memory of the controller which can be accessed via a service analyzer and is retained during a power-off period.

Claim 17

Dependent Claim 36 words

A controller according to claim 1 further comprising: a controller base, and at least one electrical hardware component of the controller simultaneously thermally grounded to said controller base and electrically insulated with respect to said base.

Claim 18

Dependent Claim 63 words

A controller according to claim 1 further comprising input voltage monitor control means for transforming an alternating current input voltage signal into a corresponding direct current voltage signal, while keeping said alternating current input voltage signal and said direct current voltage signal electrically isolated, and emitting said direct current voltage signal for use in calculating at least one control algorithm by the controller.

Claim 19

Dependent Claim 39 words

A controller according to claim 1 wherein said defrost control means calculates said maximum heat pump operating time period and said minimum heat pump operating time period also as a function of a sensed defrost time range select input.

Claim 20

Dependent Claim 62 words

In a gas heat pump system having a variable speed compressor, a controller comprising variable capacity control means for computing a compressor speed, an indoor blower speed, and an outdoor fan speed of said gas heat pump system as a function of at least one thermostat output signal in real-time at variable capacity heating/cooling load requirements of the gas heat pump system.

Claim 21

Dependent Claim 62 words

In a gas heat pump system having a variable speed compressor, a controller comprising variable capacity control means for computing a compressor speed, an indoor blower speed, and an outdoor fan speed of said gas heat pump system as a function of at least one thermostat output signal in real-time at variable capacity heating/cooling load requirements of the gas heat pump system.

Claim 22

Dependent Claim 98 words

In a gas heat pump system having a variable speed compressor, a controller comprising defrost control means for calculating a maximum heat pump operating time period between successive defrost cycles and a minimum heat pump operating time period of each said defrost cycle during a heating mode of the gas heat pump system as a function of a sensed time, a sensed time to defrost select input, a temperature, and variable capacity operating conditions, and said controller communicating with at least one component of said gas heat pump system for overall control of said gas heat pump system.

Claim 23

Dependent Claim 98 words

In a gas heat pump system having a variable speed compressor, a controller comprising defrost control means for calculating a maximum heat pump operating time period between successive defrost cycles and a minimum heat pump operating time period of each said defrost cycle during a heating mode of the gas heat pump system as a function of a sensed time, a sensed time to defrost select input, a temperature, and variable capacity operating conditions, and said controller communicating with at least one component of said gas heat pump system for overall control of said gas heat pump system.

Claim 24

Dependent Claim 103 words

In a gas heat pump system having a variable speed compressor, a controller comprising variable capacity control means for computing a compressor speed, an indoor blower speed, and an outdoor fan speed of said gas heat pump system as a function of at least one thermostat output signal in real-time at variable capacity heating/cooling load requirements of the gas heat pump system, engine control means for directly controlling and monitoring an engine of said gas heat pump system, and said engine control means interfaced with said variable capacity control means for exchanging commands from said controller and data from said engine control means.

Claim 25

Dependent Claim 103 words

In a gas heat pump system having a variable speed compressor, a controller comprising variable capacity control means for computing a compressor speed, an indoor blower speed, and an outdoor fan speed of said gas heat pump system as a function of at least one thermostat output signal in real-time at variable capacity heating/cooling load requirements of the gas heat pump system, engine control means for directly controlling and monitoring an engine of said gas heat pump system, and said engine control means interfaced with said variable capacity control means for exchanging commands from said controller and data from said engine control means.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1998-08-07	1999-02-06	1999-08-08	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2002-08-07	2003-02-06	2003-08-08	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2006-08-07	2007-02-06	2007-08-08	$7700.00	Window Closed / Lapsed

Microprocessor-based controller

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