Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23N—REGULATING OR CONTROLLING COMBUSTION
  • F23N5/00—Systems for controlling combustion
  • F23N5/24—Preventing development of abnormal or undesired conditions, i.e. safety arrangements
  • F23N5/242—Preventing development of abnormal or undesired conditions, i.e. safety arrangements using electronic means
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23N—REGULATING OR CONTROLLING COMBUSTION
  • F23N5/00—Systems for controlling combustion
  • F23N5/20—Systems for controlling combustion with a time programme acting through electrical means, e.g. using time-delay relays
  • F23N5/203—Systems for controlling combustion with a time programme acting through electrical means, e.g. using time-delay relays using electronic means
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23N—REGULATING OR CONTROLLING COMBUSTION
  • F23N2223/00—Signal processing; Details thereof
  • F23N2223/08—Microprocessor; Microcomputer
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23N—REGULATING OR CONTROLLING COMBUSTION
  • F23N2225/00—Measuring
  • F23N2225/08—Measuring temperature
  • F23N2225/18—Measuring temperature feedwater temperature
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23N—REGULATING OR CONTROLLING COMBUSTION
  • F23N2225/00—Measuring
  • F23N2225/08—Measuring temperature
  • F23N2225/19—Measuring temperature outlet temperature water heat-exchanger
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
  • F23N—REGULATING OR CONTROLLING COMBUSTION
  • F23N2227/00—Ignition or checking
  • F23N2227/02—Starting or ignition cycles

Definitions

• the present invention relates generally to boiler control systems and more specifically to a boiler control system for use with only one boiler or with multiple boilers.
• the present invention relates specifically to a Boiler Interface Controller, a Human Interface Panel and a Fault Tolerant Multiple Boiler Sequencer. The system will be explained with reference to hot water boiler(s) but it is understood that it applies as well to water heater(s).
• thermostat to boiler control has traditionally been handled by an electromechanical control that presents a digital (on or off) request for heat to a flame safety controller that would actuate a gas valve and purge system on a typical gas boiler.
• microprocessor-based controls many new features allow display and control of thermostat information, e.g., setpoint information and control point status on an annunciator screen.
• Flame safety boiler controls directly affect those elements that may cause an unsafe condition. Flame safety controls have very high safety standards and require strict testing and failure analysis, particularly for microprocessor-based controls. This level of safety and control can demand extra dollar value in the market place due to the liability issues and the difficulty of implementing controls that meet these safety standards.
• Customization and feature enhancements of flame safety controllers are prohibitively expensive, due to the cost of certification and testing.
• Components of the gas flame safety controller ignition cycle include safety checks, pre-purge, igniter surface preparation, trial for ignition, gas valve actuation, ignition, and post-purge.
• Manufacturers of flame safety products typically provide flame safety controllers to an original equipment manufacturer (OEM) for boilers. The OEM then integrates these controls into their boiler designs.
• OEM original equipment manufacturer
• Some of the boiler control products also incorporate temperature control sensing and setpoints into the device, but these are usually limited to single standalone boiler devices.
• VFD variable frequency drive
• BIC Boiler Interface Controller
• the present invention also relates to a Human Interface Panel (HIP) for use with a Boiler Interface Controller (BIC) that may be used with systems having only one boiler or having multiple boilers.
• HIP Human Interface Panel
• BIC Boiler Interface Controller
• the HIP will first be described for use with a BIC, but it is to be understood that the HIP of the present invention is also useful with any boiler that is arranged as described herein.
• Boiler controls require that a number of sequential events occur before the controlled ignition of gas in the boiler occurs. Examples of these events include but are not limited to proof of water flow, proof of satisfactory gas pressure, and proof of combustion fan operation. If any of these and other events fail to be proven, then the sequence of events that normally leads to controlled ignition is halted and the cause of a lightly loaded system could have its requirements met by using only 1 of 3 smaller, more efficient boilers instead of using 1/3 the capacity of a larger boiler.
• the present invention solves these and other needs by providing in a first aspect a method for operating a boiler including sensing a demand for heat and generating and ignition request to a flame safety controller.
• a first evaluation mode in a succession of evaluation modes then sets certain defined conditions, reads certain defined conditions and compares selected conditions. If the comparison indicates normal operation, then a next evaluation mode occurs.
• the boiler control system transitions to a failure mode if an evaluation mode is not successfully completed.
• the boiler control system provides a signal for controlling a variable firing rate boiler
• the HIP of the present invention solves these and other needs by providing a method of analyzing information from a boiler control system.
• the method includes providing a series of status modes with each status mode being represented as an input condition to be tested.
• a relative priority structure is established among the status modes and a unique message is associated with each said status mode having an input condition that is true.
• the individual status modes are then tested in an order defined by the priority structure until a status mode in a true condition is found.
• the unique message associated with the status mode found to be true is then provided on an electronic display.
• the status modes may be selected from one or more of diagnostic modes, start up modes emergency modes and stage information modes.
• the Sequencer of the present invention provides a method for controlling energy systems such as multiple boiler systems to meet an energy need.
• a controller is configured as a sequencer and the remaining controllers act as individual boiler controllers.
• the energy need is determined by measurements at the sequencer.
• Individual boiler controllers periodically send status messages to the sequencer and a record of runtimes of the boilers is maintained at the sequencer.
• the sequencer periodically sends control commands to the boiler controllers to add or delete boilers.
• the control commands give consideration to the runtimes of the boilers.
• FIG. 2 is a functional block diagram of a Boiler Interface Controller (BIC) according to the principles of that invention.
• BIC Boiler Interface Controller
• FIG. 3 is a functional block diagram of a Human Interface Panel (HIP) for use with one BIC according to the principles of the HIP invention.
• FIG. 4 is a functional block diagram of a Human Interface Panel for use with a
• FIG. 5 is a contextual software drawing of the Sequencer and modular boiler system of FIG. 4.
• FIG. 6 is an illustration of certain details of the Sequencer of FIGS. 4 and 5.
• FIG. 7a and FIG. 7b are a diagram illustrating an overview of the operation of the BIC invention of FIG. 2.
• FIG. 8 is a flowchart diagram illustrating the operation of the BIC invention in the idle mode, mode 0.
• FIG. 9a is a flowchart illustrating the operation of the BIC invention in the water flow evaluation mode, mode 1.
• FIG. 9b is a flowchart illustrating the operation of the BIC invention in the water flow failure mode, mode 1A.
• FIG. 9c is a flowchart illustrating the operation of the BIC invention in a water flow test routine, Tl .
• FIG. 10a is a flowchart illustrating the operation of the BIC invention in the low gas pressure evaluation mode, mode 2.
• FIG. 10b is a flowchart illustrating the operation of the BIC invention in the low gas pressure failure mode, mode 2A.
• FIG. 10c is a flowchart illustrating the operation of the BIC invention in a low gas pressure test routine, T2.
• FIG. 1 la is a flowchart illustrating the operation of the BIC invention in the low air evaluation mode, mode 3.
• FIG. 1 lb is a flowchart illustrating the operation of the BIC invention in the low air failure mode, mode 3A.
• FIG. 1 lc is a flowchart illustrating the operation of the BIC invention in a low air test routine, T4.
• FIG. 12a is a flowchart illustrating the operation of the BIC invention in the blocked drain evaluation mode, mode 4.
• FIG. 12b is a flowchart illustrating the operation of the BIC invention in the blocked drain failure mode, mode 4A.
• FIG. 12c is a flowchart illustrating the operation of the BIC invention in a blocked drain test routine, T4.
• FIG. 13a is a flowchart illustrating the operation of the BIC invention in the prepurge evaluation mode, mode 5.
• FIG. 13b is a flowchart illustrating the operation of the BIC invention in the soft lockout mode, mode 5A.
• FIG. 14a is a flowchart illustrating the operation of the BIC invention in the ignition evaluation mode, mode 6.
• FIG. 14b is a flowchart illustrating the operation of the BIC invention in the flame failure mode, mode 6A.
• FIG. 14c is a flowchart illustrating the operation of the BIC invention in a flame failure test routine, T5.
• FIG. 15 is a flowchart illustrating the operation of the BIC invention in the boiler on evaluation mode, mode 7.
• FIG. 16 is a flowchart illustrating the operation of the BIC invention in the heat mode, mode 8.
• FIG. 17 is a flowchart illustrating the operation of the BIC invention in the post purge preparation mode, mode 9A.
• FIG. 18 is a flowchart illustrating the operation of the BIC invention in the post purge mode, mode 9B. processing within a node.
• Nodes typically contain the Neuron Chip, a power supply, a communications transceiver, and interface electronics.
• the Neuron Microprocessor is part of the LonWorks® technology that is a complete platform for implementing control network systems.
• the LonWorks networks consist of intelligent devices or nodes that interact with each other, communicating over pre-defined media using a message control protocol.
• the processor is programmed using the LonBuilder Workstation hardware and software in Neuron-C (the language for the Neuron chip).
• the firmware application is developed using the LonBuilder development station.
• the application generated by the LonBuilder Development software environment is compiled and stored in the custom EPROM for use by the node during execution.
• the programming will have to be appropriately modified.
• BIC 10 is implemented in firmware in BIC 10 as is shown in a single boiler configuration in FIG. 2 including boiler temperature control module 28, bypass temperature control module 32, and status and mode control module 34.
• BIC 10 is shown interfacing to various elements of a boiler control system for controlling a boiler for heating a medium which is typically water.
• Temperature control module 28 receives signal 36 from sensor 22 located in the boiler supply water, signal 38 from sensor 24 located in the boiler return water, and signal 44 from sensor 42 located in outdoor air.
• Boiler temperature control module 32 also provides for receiving a setpoint signal related to a desired control set point signal.
• Bypass temperature control module 32 receives signal 40 from bypass temperature sensor 26 and provides signal 46 to bypass valve 20. Module 32 provides for receiving a set point signal.
• BIC 10 as well as the Human Interface Panel and the Fault Tolerant Multi-Boiler
• Sequencer described herein may be prepared for a particular boiler installation using a configuration tool which is external to BIC 10.
• Flame safety controller 30 provides an ignition command 54 to ignition element 56, a gas valve command 58 to gas valve 60 and a variable frequency drive (VFD) command 62 to variable speed combustion/purge motor 18.
• VFD variable frequency drive
• Status and mode control module 34 of BIC 10 in its preferred form receives signal 70 as to the "on” or “off status of ignition element 56, signal 72 as to the “on” or “off status of gas valve 60, signal 64 as to the status of combustion/purge fan 18, signal 76 as to the status of pump 12 and signal 78 as to the status of flame safety controller 30.
• Boiler temperature control module 28 of BIC 10 provides a VFD speed control signal 74 to variable speed combustion/purge motor 18. Now that certain aspects of BIC 10 have been disclosed, the operation can be set forth and appreciated.
• Boiler temperature control module 28 utilizes supply water temperature signal 36, outdoor air temperature signal 44 (optional), the setpoint of module 28 and an internal algorithm to cause an internal call for heat condition within BIC 10 and to issue external request for heat signal 52.
• a space temperature sensor could have been connected as an input to module 28 to allow the internal call for heat condition to be a function of space temperature.
• BIC 10 The operation of BIC 10 is best understood by reference to the state diagram shown in FIG.7a and FIG.7b, which identifies the modes and transitions between modes and then by reference to a flowchart that provides the details ofa specific mode.
• the BIC mode state transition diagram is intended to be used in a task scheduled environment.
• the scheduling mechanism should schedule the state transition software to run on a regular nominal 1 -second interval.
• the state information is stored between task executions in the nvoData.Mode variable to maintain the last known boiler state.
• This will allow the software executive to multi-task and perform other operations between successive state transition tasks, and allow other functions to be performed without loosing the last known state of the boiler.
• This allows efficient use of the host microprocessor and computer system resources.
• the various modes are designated in FIGS. 7a and 7b by a reference numeral corresponding to the mode designation preceded by the numeral 7, for example mode 1 is designated as 7-1. For simplicity it may also be referred to herein as Mode l.
• Mode l With reference to FIG. 7a, in Mode 0, Idle mode, the BIC has no call for heat and is awaiting a signal to start heating. If the call for heat is on, then initiate transition 7-12 to mode 1, water flow evaluation.
• the order of electrical wiring of boiler safety switches for example water flow and gas pressure, is to correspond with the order of the modes related to these switches.
• Transitions out of Mode 1 If the call for heat is off, then initiate transition 7-14 to mode 0. If the Low Water Flow input is on and has been on for a predetermined time, then initiate transition 7-16 to Mode 1A, Water Flow Fail Mode. If the Low Water flow input is satisfactory, then initiate transition 7-18 to Mode 2, Gas Pressure Evaluation.
• Transitions out of Mode 2A If the call for heat is off, then initiate transition 7- 32 to mode 0. If the Gas Pressure Fail input is OFF, then initiate transition 7-34 to Mode 2. Transitions out of mode 3: If the call for heat is off, then initiate transition 7-36 to mode 0. If the Low Water Flow input is low, then imtiate transition 7-38 to Mode 1A. If The Gas Pressure Fail input is ON, then initiate transition 7-40 to mode 2 A. If the Low air input is ON, then initiate transition 7-42 to mode 3 A Low Air Fail. If Low air input is off, and all tests are complete, then initiate transition 7-44 to Mode 4 Block Drain.
• Transitions out of Mode 3 A If the call for heat is off, then initiate transition 7- 46 to mode 0. If the Low air input is off then initiate transition 7-48 to Mode 3. Transitions out of Mode 4: If the call for heat is off, then initiate transition 7-50 to mode 0. If the Low Water Flow input is on, then initiate transition 7-52 to Mode 1 A. If The Gas Pressure Fail input is on, then initiate transition 7-54 to mode 2 A. If the Low air input is on, then initiate transition 7-56 to mode 3 A. If Block drain input is on, then initiate transition 7-58 to Mode 4A Block Drain. If Block drain input is off, and all tests are complete then initiate transition 7-60 to Mode 5, Prepurge.
• Transitions out of Mode 4 A If the call for heat is off, then initiate transition 7- 62 to mode 0. If the Low air input is off then initiate transition 7-64 to Mode 4.
• Transitions out of Mode 5 If the call for heat is off, then initiate transition 7-66 to mode 0. If the Low Water Flow input is on, then initiate transition 7-68 to Mode 1A.
• Transition out of Mode 5 A If the call for heat is off, then initiate transition 7-82 to Mode 0. Refer to flowcharts for conditions for transition 7-80. Transitions out of Mode 6: Refer to flow charts for conditions for transition 7-88 to Mode 5A, transition 7-92 to Mode 5A, transition 7-90 to Mode 6A, transition 7-86 to 60 Sec timer and transition 7-94 to Mode 7 Boiler On Evaluation.
• Transitions out of Mode 6 A If the call for heat is off, then initiate transition 7- 96 to mode 0. If the Low Water Flow input is on, then initiate transition 7-98 to Mode 1A
• Transitions out of Mode 7 Refer to flow charts for conditions for transition 7- 100 to Mode 9A, Post Purge Prepare, and transition 7-102 to Mode 8, Heat.
• Transitions out of Mode 8 Refer to flow charts for transition 7-104 to Mode 9, Bypass Temp Control, and transition 7- 110 to Mode 9A Post Purge Prepare. 8A, Bypass Temperature Control represents the control of valve 20 from bypass temperature 26 and bypass temperature control 32. Transitions out of Mode 9 A: Refer to flow chart for transition 7-112 to Mode
• mode 1 A As shown in FIG. 9b is initiated.
• Mode 1A provides for a predetermined number of cycles, e.g., 5 cycles or 5 seconds. If water flow is not satisfactorily proven in this time, then a water flow test routine is initiated which results in water flow failure shutdown of the boiler.
• BIC has will be highly useful information for performance evaluation and troubleshooting of boiler systems.
• BIC 10 In the event of a boiler failure the use of BIC 10 will permit a boiler service person to quickly diagnose many problems. Using only typical portable testing devices, e.g. a volt-ohm-meter, a service person can determine at what point in the boiler operating sequence a problem exists. In addition, more sophisticated diagnostic tools such as a laptop or handheld device may be used to query nodes and perform other diagnostic tests. That is, through the monitoring of the modes, or outputs, or alarms of BIC 10, the service person can easily isolate the problem and take action to correct the problem and restore boiler operation.
• typical portable testing devices e.g. a volt-ohm-meter
• BIC 10 has been explained by describing its application to a boiler for a heating system. BIC 10 is also very useful in the control of water heaters. Certain features of BIC 10, for example the reset of the water temperature setpoint as a function of the outdoor air temperature would not be used in the water heater application.
• Temperature control module 28a receives signal 36a from sensor 22a located in the boiler supply water, signal 38a from sensor 24a located in the boiler return water, and signal 44a from sensor 42a located in outdoor air. BIC 10 also provides for receiving a setpoint signal related to a desired control setpoint signal. Bypass temperature control module 32a receives signal 40a from bypass temperature sensor 26a and provides signal 46a to bypass valve 20a.
• Permanent configuration information on identification structure and address of information is stored permanently in electrically erasable memory or flash memory 120.
• Keypad 122 is used to select information for display and to move to different displays, e.g. from the status of individual boilers within a group of boilers to individual status values within a specific boiler.
• the HIP of the present invention is a single status variable that can display the current status of an individual boiler or a system that includes a group of boilers.
• the display includes status information such as single stage firing status, multiple stage firing status, safety conditions, pre-purge, post purge, unknown safety, ignition evaluation, and post purge preparation.
• the HIP provides monitoring of flame safety controller status, and active management of non-flame-safety mode changes in a real time temperature control environment.
• the HIP invention in the specific embodiment shown utilizes the Status_ Mode display variable. This technique consolidates critical system functions and error information in one efficient variable structure using the LonWorks protocol to transfer information from the boiler devices. This data structure can be transferred to a low cost peer to peer device through the Echelon bus.
• BIC 10 is configured with modules as shown in FIG. 4 including system temperature control module 202, outdoor air reset module
• Multiple boiler arbitration logic module 102a has a number of additional inputs including system factory test 264, system waterflow 266, manual 268, low gas pressure 270, pump status 272, freeze protection 274, disabled mode 278 and emergency mode 280. For simplicity, only representative inputs are shown.
• Arbitration logic module 102a responds through a network interface module (not shown) with arbitration encoded signal 282 which is received by network interface module 228 and provided to CCD 104.
• the functioning of CCD 104 in the multiple boiler implementation is as described under the HIP 100 description for the single boiler embodiment and includes the ability to display status information from a multiple boiler system as well as individual boilers within the multiple boiler system.
• the single status variable from the Temperature controller allows the monitor boiler system status displayed in a hard real time, state machine task environment that will not require uninterrupted and sequential access to conditions.
• Safety and Health Factor Hot Water boilers, gas boilers, high-pressure steam, and boiler devices are prone to very critical safety issues.. Traditionally these safety issues are solved through extremely stringent regulations on boiler manufacturers concerning "flame safety" devices and rigid safety mode analysis.
• One area that has not been exploited is to use the non-flame safety status of the boiler and display this information to the user in an intelligent combination that provides safety diagnostic information, and allows monitoring of the boilers for characteristics of unsafe conditions (such as flame fail or repeated attempts at ignition) that will allow tracking of problems before they start.
• characteristics of unsafe conditions such as flame fail or repeated attempts at ignition
• the UNVT_Status_Mode display variable By using, in the preferred mode, the UNVT_Status_Mode display variable to transfer information from the boiler devices, significant cost reductions of interface can be achieved and realized by consolidation of critical system functions and error information in one very efficient variable structure.
• This data structure can be transferred to a low cost peer to peer device through the Echelon bus, which provides for interoperability, interoperability standards, cross-industry support, and low cost interface.
• Ease of use no Boiler operation knowledge is necessary, as all information is available "at a glance" from HIP main view screen. This ergonomically pleasing display is easy and compelling for the user to interact with and can easily be used to evaluate complete boiler system status.
• Ease of production Due to the significantly reduced complexity of the display and general-purpose interface of the display, the end device could be produced very inexpensively. Multiple HIP devices could be added to the system as both a local and remote display. Subsets of Boiler Data and System Data could be displayed from the local device or at a remote location such as the System engineers office, or the Church Custodians or Fast Food Restaurant Managers office. Durability: Since there is no remote relay connections and wiring, the traditionally expensive and complex remote status display is now very cost effective, and is supported by true 3 rd party interoperability with a ubiquitous and commodity interface.
• Enhancements can add new features that depend on the mode behavior such as state monitors, dial in tools to bus, and combinations product that would combine for instance VFD efficiency and air/fuel ratio tuning.
• Boiler systems that utilize a number of modular boilers require a control system that provides for the sequencing of the modular boilers.
• Certain aspects of fault tolerant multi-node stage sequencing controller 200 were partially explained in relation to arbitration logic module 102a in the explanation of the use of HIP 100 with multiple boilers.
• the operation of sequencing controller 200 may be represented as illustrated in FIG. 5 including a Sequencer Node 300 and a stage node 380.
• Sequencer node 300 is a temperature control device that monitors the system control temperatures and makes decisions to actively manage multiple-stage node analog control level and on/off stage decisions changes such as and adding and removing functioning stages.
• Analog stage controller 312 provides firing rate system signal and status signal 336 to runtime mode stage controller 304.
• Stage status array 306 receives stage number and firing rate signals 338 from runtime and mode stage controller 304 and provides stage status signal 340 to controller 304.
• Stage status array 306 receives boiler identification (ID), mode and run time information signal 342 from interface controller 316 and provides communications formatted signal 344 to controller 316.
• Stage Node 330 is an active communications and control node that interfaces to an active energy source. In the context of boiler systems, stage node 330 may be a boiler interface controller such as BIC 10 that interfaces to a flame safety controller 30 and to various sensors, boiler safeties and status signals as previously described herein. Stage node 330 implements decisions made in sequencer node 300 algorithms for control relating to analog firing rate and the addition or deletion of a stage. Information on runtime, control status, and safeties is communicated back to Sequencer Node 300.
• the present invention is a multi-node sequencing controller (based on stage runtime), which uses the runtime and node stage controller piece to process unique data- collecting information stored in the stage data array.
• stage runtime uses the decision technique implemented in the runtime and mode stage controller, operations and total runtime hours from the modular stages to process unique data- collecting information stored in the stage data array.
• Sequencing controller 200 provides a method to control dynamic loading and staging of boiler stage node functionality such as mode progression monitoring, pre- purge speed, pre-ignition speed control, Heat evaluation mode, and post purge ignition shutdown capabilities.
• all mode monitoring and transitions present in the stage node can be implemented without interfering with the sequencer nodes staging requests.
• sequencer node 300 can dynamically adjust the control of the remaining multiple stages individually of a high efficiency condensing, automatic bypass control, modulating firing rate boiler by taking into account the failed status and readjusting the load dynamically independent of the source control algorithm.
• Sequencer node 300 uses an efficient array to collect and rank boiler interface controllers based on the runtime and mode stage controller. A more complete understanding of the Sequencer invention may be obtained from Pseudocode included as an Appendix and the following information regarding data structure herein. Data structure 1, Stage Array [0 to 16] in Sequencer
• FIG. 19 is a functional block diagram of a network which provides automatic self-configuration of controllers acting as nodes on a network according to the principles of that invention.
• FIGS. 20a through 20d are flowcharts illustrating a portion of the operation of the HIP invention of FIGS. 3 and 4.
• FIG. 22 is an example of a menu according to the principles of the HIP invention of FIGS. 3 and 4. DESCRIPTION OF THE PREFERRED EMBODIMENT
• a boiler interface controller (BIC) for use in a single boiler arrangement according to the teachings of the present invention is shown in the figures and generally designated 10.
• BIC 10 is shown for interfacing with a flame safety controller 30, which provides the required flame safety functions.
• BIC 10 in the preferred embodiment employs a Neuron (a registered trademark of Echelon Corp.) microprocessor that is well adapted to building control system networks.
• Neuron a registered trademark of Echelon Corp.
• the Neuron Chip Distributed Communications and Control Process includes three 8-bit pipelined processors for concurrent processing of application code and network packets.
• the 3150 contains 512 bytes of in-circuit programmable EEPROM, 2048 bytes of static Ram, and typically 32768 bytes of external EPROM memory.
• the 3150 typically uses a 10 MHz clock speed. Input/Output capabilities are built into the microprocessor.
• the LonWorks® firmware is stored in EPROM and allows support of the application program.
• the Neuron Chip performs network and application-specific the failure must be investigated and corrected. In the past when this occurs the only known fact is likely to be that the boiler is not functioning and this may only become known after the occupied space served by the boiler is no longer heated to a comfort condition.
• Boilers are complicated devices that should be periodically inspected and the necessary sequential events that lead to controlled ignition of gas should be observed by a qualified boiler service person to determine that they are properly functioning. Testing or diagnostic tools that enable the service person to observe the sequential events will help to assure that the boiler is functioning properly.
• the present invention also relates to a Fault-tolerant Multi-Node stage Sequencer.
• the design of boiler systems for commercial, industrial, and institutional buildings is typically performed by a consulting engineer, who specifies the type, number, and size of boilers needed for heating systems. There are many factors that weigh into the decisions an engineer makes when selecting and sizing boilers for a heating system including capacity of the system, what is the load present on the system, and what is the worst case load conditions that would be required for the system to provide adequate heat.
• the pseudocode contained in the Appendix illustrates a sequence referred to as Efficiency Optimized with Runtime.
• This Sequence provides a technique for adding capacity by turning on a boiler having the lowest runtime and reducing capacity by turning off a boiler having the highest runtime.
• variations or options may be implemented. For example one option could employ a first on/first off sequence as capacity is reduced. Another option could employ operating boilers at a capacity that is most efficient. For example, if the highest efficiency occurs at minimum loading, then this option would add a boiler when the load is such that the added boiler can run at minimum capacity. For example, if boiler number 1 reaches a 60% load, then boiler number 2 could be added such that both boilers can operate at 30% loading.
• Other variations will be apparent to those of ordinary skill in the art.
• Sequencer 200 has been described in terms of its application to a boiler control system or hot water system it is not limited to these uses. Sequencer 200 may be used to stage other energy systems, for example water chillers or electric generators.
• This invention resides in the Node firmware portion of the control system and provides for binding ofa minimally configured supervisory/ client control node system.
• Supervisory Node/Client Node Binding & Configuration Procedure 1 The firmware in the client nodes is the same as the firmware in the supervisory node.
• node 402 By the use of a digital or analog input, the node with a short (digital) or resistive value set (analog) to a fixed special value at the input, node 402 is identified as the supervisory node.
• the internal programming of the controller automatically changes the configuration parameter network variable nciConfig.
• Application Type to Type "Supervisory Node to 16 nodes"- providing nci ConfigSrc is set to CFGJ OCAL showing that no configuration tool has changed any configuration parameters. 6.
• NvoClientlD contains nviClientlD .NIDOut (a 6- character NID string) and the ClienflDOut field which contains the Client ID (0-254) of the client node. Initially all the client Ids are set to 0 (unconfigured). 7. All non-supervisory Nodes discard the nviClientlD information, but the Supervisory stores the nvoClientlD information into and array and sorts them by NID (Neuron ID). For example:
• NvoBoilerStatus ApplicMode HEAT l byte ENUMERATION Current Polled From (See table 1 (BYTE) Application Mode Boiler to HIP or for list of of type of to be monitoring node Enumerations) STATUS MODE commanded to the boiler - See Table 1 for possible values
• Boiler Status display variable is a result of an arbitration of many different operating and failure modes, resulting in an extremely useful and pertinent information status on the boiler.
• the result of this synthesis of grouping structures and boiler system status information/firing rate in one menu allows dense; information disclosure of 48 arbitrated operating mode and firing rate information on a controller.
• Enumerations of the Boiler Status Information variable structure are listed in Table 1.
• the system level menu of FIG.22 is the primary display associated with the Boiler System.
• the meaning of the system level information on a line by line basis may be explained as follows:
• the sequencer is requesting Boiler #2 to produce heat at 17% of capacity and is functioning normally in the Heat Mode.

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• 2000
  • 2000-12-15 US US09/739,085 patent/US6536678B2/en not_active Expired - Lifetime
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