U.S. patent application number 12/254507 was filed with the patent office on 2009-04-16 for html driven embedded controller.
This patent application is currently assigned to YORK INTERNATIONAL CORPORATION. Invention is credited to Delmar Eugene LEHMAN, Dennis R. THRUSH.
Application Number | 20090099668 12/254507 |
Document ID | / |
Family ID | 35094546 |
Filed Date | 2009-04-16 |
United States Patent
Application |
20090099668 |
Kind Code |
A1 |
LEHMAN; Delmar Eugene ; et
al. |
April 16, 2009 |
HTML DRIVEN EMBEDDED CONTROLLER
Abstract
A method and system is provided for gathering, processing,
displaying, and manipulating data from building equipment using a
dedicated HTML-driven, non-PLC controller having an integral web
server. Authorized users who use microprocessor controlled devices
to access the website are provided with displayed equipment data
that can be selected, monitored, and adjusted based on a user
profile controlled by software of the controller.
Inventors: |
LEHMAN; Delmar Eugene;
(Chambersburg, PA) ; THRUSH; Dennis R.;
(Chambersburg, PA) |
Correspondence
Address: |
MCNEES WALLACE & NURICK LLC
100 PINE ST., P.O. BOX 1166
HARRISBURG
PA
17108-1166
US
|
Assignee: |
YORK INTERNATIONAL
CORPORATION
York
PA
|
Family ID: |
35094546 |
Appl. No.: |
12/254507 |
Filed: |
October 20, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11179315 |
Jul 12, 2005 |
7440809 |
|
|
12254507 |
|
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60587920 |
Jul 14, 2004 |
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Current U.S.
Class: |
700/80 ; 700/83;
715/772; 726/4 |
Current CPC
Class: |
G05B 19/058 20130101;
G05B 2219/2614 20130101; G05B 19/4186 20130101; Y02P 90/02
20151101; G05B 2219/2638 20130101; G05B 2219/31457 20130101; Y02P
90/185 20151101; G05B 19/0428 20130101; G05B 2219/34444 20130101;
G05B 2219/31085 20130101 |
Class at
Publication: |
700/80 ; 726/4;
715/772; 700/83 |
International
Class: |
G05B 9/02 20060101
G05B009/02; H04L 9/32 20060101 H04L009/32; G05B 15/00 20060101
G05B015/00; G06F 3/048 20060101 G06F003/048 |
Claims
1. A system for remotely monitoring building equipment, the system
comprising: at least one item of building equipment; a non-PLC
controller communicably connected to the at least one item of
building equipment to receive data from the building equipment, the
non-PLC controller having a web server, a microprocessor and a
memory storing a computer program executable by the microprocessor,
the computer program comprising computer instructions to: gather
data from the connected building equipment; capture the data in CGI
scripts; populate the data into tags provided in an HTML web page
generated by the web server of the non-PLC controller; permit a
user to log on to the web server using an HMI device; prompt the
user to enter a user name and password; recognize the user name and
password and associate the user name and password with a stored
user profile having an access level for the recognized user; and
send data using the web server to the user; wherein, the data sent
to the user corresponds with the access level and includes
instructions to generate a display for the user having
predetermined display characteristics associated with the stored
user profile.
2. The system of claim 1, wherein the building equipment is
selected from the group consisting of heating, ventilation, air
conditioning, and refrigeration equipment.
3. The system of claim 1, wherein the data is selected from the
group consisting of alarms and faults, operational status, mode,
settings, operating parameters, historical parameters, and
combinations thereof.
4. The system of claim 3, wherein the operating parameter is
selected from the group consisting of: compressor speed, fan speed,
thermostat setting, refrigerant level, temperature, pressure,
compressor capacity, motor amps, and combinations thereof.
5. The system of claim 3, wherein the building equipment is a
compressor of an HVAC&R system, and wherein the operating
parameter is selected from the group consisting of: capacity slide
position, volume slide position, suction pressure, discharge
pressure, oil pressure, main oil injection pressure, economizer
pressure, filter pressure, intermediate pressure at an intermediate
stage of compression, balance piston pressure, system discharge
pressure, suction temperature, discharge temperature, oil
temperature of the compressor, oil separator temperature,
process/brine temperature leaving, process/brine temperature
entering, motor current, motor amps, motor and compressor speed,
compressor vibration during suction, compressor vibration during
discharge, motor vibration at a shaft side, motor vibration at an
opposite shaft side, and combinations thereof.
6. The system of claim 3, wherein the historical parameters are
selected from the group consisting of: run time, downtime, and
maintenance.
7. The system of claim 1, wherein date gathering from the building
equipment is performed automatically at predetermined intervals
selected by a user.
8. The system of claim 1, wherein the gathered data is
automatically retained for a preselected period of time or up to a
preselected number files by a system component having data storage
capacity.
9. The system of claim 8, wherein the preselected period of time
can be adjusted by a user.
10. The system of claim 8, wherein the gathered data is
automatically deleted when another CGI script is transmitted to
populate the HTML web page.
11. A system for remotely monitoring building equipment, the system
comprising: at least one item of building equipment; a non-PLC
controller communicably connected to the at least one item of
building equipment to receive data from the building equipment, the
non-PLC controller having a web server, a microprocessor and a
memory storing a computer program executable by the microprocessor,
the computer program comprising computer instructions to: gather
data from the connected building equipment; capture the data in CGI
scripts; populate the data into tags provided in an HTML web page
generated by the web server of the non-PLC controller; permit a
user to log on to the web server using an HMI device; prompt the
user to enter a user name and password; recognize the user name and
password and associate the user name and password with a stored
user profile having an access level for the recognized user; and
send data using the web server to the user, wherein the data sent
to the user corresponds with the access level and includes
instructions to display the HTML web page using predetermined
display characteristics associated with the stored user profile,
wherein the data further includes computerized instructions
executable by the HMI device for allowing the user to manipulate
the sent data, and to return the user-manipulated data to the
controller to modify an operating parameter of the building
equipment; and at least one HMI in communicable connection with the
web server to receive the HTML web page.
12. A method of monitoring and controlling building equipment, the
method comprising the steps of: providing a system for remotely
monitoring building equipment, the system comprising: at least one
item of building equipment, a non-PLC controller communicably
connected to the at least one item of building equipment to receive
data from the building equipment, the non-PLC controller having a
web server, a microprocessor and a memory storing a computer
program executable by the microprocessor; automatically polling the
connected building equipment at preselected intervals using the
non-PLC controller; gathering data from the connected building
equipment; incorporating the gathered data into CGI scripts using
the microprocessor of the controller; and populating tags with the
CGI scripts, the tags being provided in an HTML web page generated
by the web server of the controller.
13. The method of claim 12, further comprised of the steps of:
providing a remote interface device for use by a remote user;
permitting the remote user to access the web server using the
remote interface device; prompting the user to enter a user name
and password; recognizing the user name and password and
associating the user name and password with a stored user profile
with an access level for the user; sending data to the remote
interface using the web server, the sent data corresponding with
the access level of the user, the sent data further including
instructions executable by the remote interface device for
generating a display having predetermined display characteristics
associated with the stored user profile; displaying the sent data
on the remote interface device.
14. The method of claim 12, wherein the step of gathering data
includes gathering data relating to operating parameters of
connected building equipment, and wherein the method further
includes the steps of: comparing the gathered data to a
predetermined stored range for an operating parameter; and
automatically generating an electronic event if the gathered data
falls outside of the predetermined stored range for an operating
parameter.
15. The method of claim 14, wherein the electronic event includes a
notification that is automatically provided to the web server.
16. The method of claim 14, wherein the electronic event further
includes an electronic command that is generated by the controller
and sent back to the connected equipment, the electronic command
selected from the group consisting of a command to shutdown the
connected building equipment, and a command to modify the operation
of the connected building equipment.
17. The method of claim 14, wherein the step of automatically
generating an electronic event includes automatically notifying all
logged-on users having a predetermined user profile.
18. The method of claim 12, further comprised of the step of
allowing remote users to select, request, obtain, and manipulate
data concerning an operating parameter of the connected building
equipment.
19. The method of claim 12, wherein the connected building
equipment is a compressor of an HVAC&R system, and wherein the
operating parameter is selected from the group consisting of:
capacity slide position, volume slide position, suction pressure,
discharge pressure, oil pressure, main oil injection pressure,
economizer pressure, filter pressure, intermediate pressure at an
intermediate stage of compression, balance piston pressure, system
discharge pressure, suction temperature, discharge temperature, oil
temperature of the compressor, oil separator temperature,
process/brine temperature leaving, process/brine temperature
entering, motor current, motor amps, motor and compressor speed,
compressor vibration during suction, compressor vibration during
discharge, motor vibration at a shaft side, motor vibration at an
opposite shaft side, and combinations thereof.
20. The method of claim 17, wherein the electronic event is
selected from the group consisting of: analog board communication
failure shutdown, analog board failure shutdown, auxiliary alarm,
auxiliary shutdown, balance piston failure shutdown, compressor
auxiliary failure, compressor interlock failure, compressor
starting failure auxiliary, compressor starting failure for low
motor amps, compressor stopping failure auxiliary, compressor
stopping failure for motor amps, compressor unable to unload alarm,
dbs alarm, dbs trip, digital board reset, digital board shutdown,
digital board communication failure shutdown, discharge end
compressor vibration alarm, discharge end compressor vibration
shutdown, discharge pressure sensor fault, discharge temperature
saturation alarm, discharge temperature saturation shutdown,
discharge temperature sensor fault, false start failure auxiliary,
false start failure for motor amps, high auxiliary analog alarm,
high discharge temperature alarm, high discharge temperature
shutdown, high discharge pressure alarm, high discharge pressure
shutdown, high economizer alarm, high economizer shutdown, high
entering process temperature alarm, high entering process
temperature shutdown, high liquid level shutdown, high manifold
pressure alarm, high manifold pressure shutdown, high motor current
alarm, high motor current shutdown, high oil filter pressure alarm,
high oil filter pressure shutdown, high oil temperature alarm, high
oil temperature shutdown, high rpm alarm, high rpm shut down, high
suction pressure alarm, high suction pressure shutdown,
insufficient main oil pressure shutdown, liquid slug alarm, liquid
slug shutdown, low auxiliary analog alarm, low auxiliary analog
shutdown, low economizer alarm, low economizer shutdown, low
entering process temperature alarm, low entering process
temperature shutdown, low main oil injection pressure shutdown, low
motor current shutdown, low oil pressure alarm, low oil pressure
shutdown, low oil separator temperature alarm, low oil separator
temperature shutdown, low oil temperature alarm, low oil
temperature shutdown, low process temperature alarm, low process
temperature shutdown, low rpm alarm, low rpm shutdown, low suction
pressure alarm, low suction pressure shutdown, maintenance alarm,
missing oil pressure alarm, missing oil pressure shutdown, motor
stator temperature alarm, motor stator shutdown alarm, motor
starter communication failure shutdown, oil level shutdown, oil log
shutdown, oil pressure sensor fault, oil pump aux failure, oil pump
alarm, oil pump failure shutdown, oil temperature sensor fault,
opposite shaft side drive vibration alarm, opposite shaft side
drive vibration shutdown, opposite shaft side drive temperature
alarm, opposite shaft side drive temperature shutdown, separator
temperature sensor fault, shaft side drive vibration alarm, shaft
side drive vibration shutdown, shaft side drive temperature alarm,
shaft side drive temperature shutdown, starting failure, starting
superheat shutdown, suction end compressor vibration alarm, suction
end compressor vibration shutdown, suction pressure sensor fault,
and variable speed communications alarm.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/587,920 filed Jul. 14, 2004.
FIELD OF THE INVENTION
[0002] The present invention is directed to a system and method for
communicating or for the transport of electronic data and
information from controlled building equipment to local and
remotely located users. More particularly, this invention is
directed to a system and method for providing data and information
from particular items of controlled building equipment, such as
heating ventilation air-conditioning and refrigeration (hereinafter
"HVAC&R") equipment, to a user, such as a servicing technician
or contractor, using a dedicated Hypertext Markup Language ("HTML")
embedded, non-PLC, controller that collects and serves data to a
website generated by a web server in the controller. The website
can be accessed and reviewed by remotely located users on remotely
located devices, and can simultaneously be accessed and displayed
by other users, including users accessing a local display
preferably located on or in proximity to the controlled equipment.
Whether in local or remote access mode, the website allows
authorized users to control the equipment, and also to
independently control the display of the data from the
equipment.
BACKGROUND OF THE INVENTION
[0003] Modern buildings include sophisticated HVAC&R systems
that control the building's interior environment and/or a system
process. For example, the air conditioning component of a building
HVAC&R system includes at least one compressor, and often
several compressors, that operate in conjunction with condensers,
evaporators, fans, and other refrigeration circuit components to
dehumidify and cool the air circulating throughout the building's
interior. Ordinarily, each item of building equipment includes an
electronic control panel that permits an operator to activate,
deactivate, or adjust the speed or other operating parameter of the
building equipment. The electronic control panel is often mounted
directly on the equipment, but may alternatively be placed in
proximity to the equipment at a location more easily accessible to
the operator.
[0004] Increasingly, items of building equipment are being
networked through building automation systems ("BAS") to permit
monitoring and limited control of the equipment by technicians and
operators at on-site locations, such as a control room, that are
several feet to several hundred feet away from the operating
equipment. This allows operators to obtain data from the equipment
and to adjust operating parameters of networked equipment
accordingly. One component of such a BAS includes a Programmable
Logic Controller ("PLC") that includes a back plane for connecting
building equipment control modules to the PLC, and further includes
simple "ladder logic" for controlling the modules. Due to their
logic structure, PLCs, as opposed to microprocessors, can only
handle a very limited number of logic functions, and can only
perform a very limited number of calculations or other tasks
simultaneously. The priority task of known PLCs is to provide data
gathering for monitoring purposes, and known PLC-type controllers
inherently require attachment to other items of equipment and to a
local computer network in order to function in a BAS. The BAS is in
essence an intelligent breaker box that turns equipment on or off
at scheduled times and upon the happening of certain events. For
example, in the case of a fire, a building fire system component
would detect fire and tell the BAS to shut off lights and other
building equipment that may encourage the spread of fire. Moreover,
PLCs operating in a BAS are required to respond to a large number
of systems, and must adhere to inflexible communication protocols
by which the connected systems can connect and poll with, as well
as different protocols for communicating with and controlling the
controlled equipment. These requirements, combined with the limited
logic capability and slow processing speed of known PLCs, make PLCs
a poor choice for flexible and intelligent control of building
equipment.
[0005] Accordingly, what is needed is a non-PLC controller having a
microprocessor that permits fast and accurate gathering,
processing, and storage of data from both standalone and
BAS-networked building equipment, and also having an embedded web
server that allows a plurality of authorized users, whether local
or remote, to simultaneously access and view data, and to adjust
operation of the equipment.
[0006] Furthermore, in typical known embedded controllers, only
about twenty percent (20%) of the software program is dedicated to
control of the equipment. The remaining eighty percent (80%) is
dedicated to monitoring and permitting interaction with users, such
as at a human-machine interface device ("HMI"). Accordingly, what
is needed is a controller that separates the program code for
monitoring from the program code for equipment control in a manner
that is efficient yet invisible to users accessing the controller
through a HMI.
SUMMARY OF THE INVENTION
[0007] The present invention provides a method of locally and
remotely monitoring controlled items of building equipment has the
step of providing an item of building equipment to be controlled,
the building equipment communicably connected to a dedicated
HTML-driven, non-PLC, controller. The controller includes an
embedded web server and microprocessor executing a computer program
stored in memory. The method also includes the steps of operating
the equipment, gathering data using the controller, processing the
data in a preselected fashion based upon a user profile, serving
the data to a website, accessing the website using a
microprocessor-controlled device, and displaying the served data on
the microprocessor-controlled device. The method can further
include the steps of adjusting the display of served data based
upon a user's preferences, the preferences associated with a user
profile.
[0008] A system is provided for simultaneously locally and remotely
monitoring and controlling an item of building equipment via an
Internet website served by an HTML controller associated with the
controlled equipment. The system includes at least one item of
building equipment, an HTML-driven, non-PLC, controller
communicably connected to the at least one item of building
equipment. The controller has a microprocessor executing a computer
program that includes computer instructions to poll the equipment
and process and display the collected data in a preselected fashion
based upon a user profile. The controller of the system further
includes a web server to serve a web page to a wide area network
for access by a user through an HMI. The computer program includes
instructions to prompt the user to enter a user name and password,
to recognize the user name and password and to associate the user
name and password with a stored user profile that includes an
access level for the recognized user. The software further includes
instructions to send the data using the web server to the HMI. The
sent data corresponds with the access level of the user, and
includes instructions executable by the HMI device to generate a
display having predetermined display characteristics associated
with the stored user profile.
[0009] In another embodiment, a system for remotely monitoring
building equipment includes: at least one item of building
equipment, a non-PLC controller communicably connected to the at
least one item of building equipment to receive data from the
building equipment, and an HMI interface in communication with the
non-PLC controller. The non-PLC controller includes a web server, a
microprocessor and a memory storing a computer program executable
by the microprocessor. The computer program includes computer
instructions to gather data from the connected building equipment
and to capture the data in Common Gateway Interface ("CGI")
scripts. CGI is a standard for external gateway programs to
interface with information servers such as HTTP servers. The
computer program further includes computer instructions to populate
the data into tags provided in an HTML web page generated by the
web server of the non-PLC controller. The computer program further
includes instructions to permit a remote user to log on to the web
server using a HMI, to prompt the user to enter a user name and
password, to recognize the user name and password, to associate the
user name and password with a stored user profile that includes an
access level for the user, and to send data using the web server to
the HMI. The data sent to the HMI corresponds with the user's
access level, and further includes instructions executable by the
HMI device to generate a display having predetermined display
characteristics associated with the user profile, to allow an
authorized user to remotely access preselected data, to allow the
authorized user to manipulate the data, and to process the
user-manipulated data for return to the controller for return to
the controller to modify an operating parameter of the building
equipment.
[0010] An advantage of the present invention is that a local user
such as an on-site technician, as well as remote users such as
off-site contractors or other authorized remote users, can access
the web site of the controller and be linked with the controlled
equipment for gathering and monitoring of data, as well as for
control of the displayed parameters such as the language of text,
units of measure, and types of data displayed without disrupting
the data that may be displayed on devices of other users who are
simultaneously accessing the controller.
[0011] Another advantage of the present invention is that the use
of a website generated by a dedicated HTML-driven controller
permits data transfer from particular items of building equipment
to remotely located users, without the need for networking the
controller or item of controlled equipment to a BAS or other local
computer network.
[0012] Another advantage of the present invention is that the use
of a website generated by a dedicated HTML-driven controller
provides a quick and easy way for equipment information to be
accessed by both local and remote users.
[0013] Yet another advantage of the present invention is that it
permits a remotely located contractor to monitor numerous pieces of
equipment, including equipment located at different geographical
sites, without the need for a dedicated connection to any
non-Internet computer network(s) that might otherwise control the
building equipment.
[0014] Still another advantage of the present invention is that it
allows service personnel to troubleshoot equipment problems from
remote locations, such as their home or office, by providing access
to an Internet website generated by the controller, thus allowing
them to see exactly what an on-site operator of the equipment would
see on a local display linked to the equipment, allowing less
service calls while maintaining adequate equipment and customer
service.
[0015] Other features and advantages of the present invention will
be apparent from the following more detailed description of the
preferred embodiment, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing and other features of the present invention
will be more readily apparent from the following detailed
description.
[0017] FIG. 1 illustrates a block diagram of one embodiment of a
controller system of the present invention.
[0018] FIG. 2 illustrates a block diagram of an HMI local
controller system in accordance with the present invention.
[0019] FIG. 3 illustrates a block diagram of a network including a
non-PLC with an embedded HTML server, the controller connected to
items of building equipment, PLC controllers, and remote and local
HMIs.
[0020] Wherever possible, the same reference numbers will be used
throughout the drawings to refer to the same or like parts.
DETAILED DESCRIPTION OF THE INVENTION
[0021] A system is provided to facilitate monitoring and control of
particular items of building equipment, including stand-alone and
networked items of equipment (such as in a BAS), by locally and
remotely located users, such as on-site technicians and off-site
service contractors. The system includes an HTML driven embedded
controller for HVAC&R equipment and other building systems, and
methods that permit remote access and remote control of the
controller and associated equipment through an Internet-based
website.
[0022] In one embodiment, the controller of the present invention
includes a microprocessor (also known as a Central Processing Unit
or "CPU") that can generate an interface for a user to control an
item of equipment. The interface is presented as a web page that is
generated by a web server incorporated in the controller. The web
page can be directly viewed on a connected local display screen.
Additionally, because the interface is provided as a web page
having a unique web site or IP (Internet Protocol) address, the
interface can be accessed directly by remote users using virtually
any web browser with a connection to the Internet. Access to the
website, as well as authorization to monitor and control connected
equipment, is controlled by any known means for secure computerized
access, such as user lists, passwords, user profiles, and
permissions.
[0023] The controller interface utilizes HTML and CGI scripts to
generate the web page and to populate the web page with relevant
data from connected equipment, thereby allowing a live, real-time
or near real-time display of data from the controller and connected
equipment. Population of the web page with data is achieved by
providing HTML tags that are interpreted by CGI scripts that
gather, format, and return data to the web server of the
controller. The web server provides a web page with the resulting
information to the local display screen, as well as to remote
devices connected to the web server over the Internet or through
serial/USB ports. The generated web pages provide remote users with
identical real-time information to that of the local display screen
of the equipment, and preferably have the same appearance, layout
and operation as the local display screen so that all users feel as
though they are standing at the local display screen of the
equipment. The result is that local and remote users, such as in
various parts of the world, have the ability to gain access to the
controller separately or together, yet independently of one
another, for the purpose of monitoring, manipulating, servicing,
trending, and maintenance of the equipment.
[0024] Significantly, the controller of the present invention
includes a dedicated microprocessor, rather than a programmable
logic controller (PLC) to control connected equipment. The benefit
of the microprocessor is that it can multi-task to run control,
monitoring, display, and web server functions simultaneously.
Moreover, because all of the above functions are performed by the
microprocessor of the controller, the controller is not required to
be connected to a PLC or Building Automation System (BAS). This is
a significant improvement over PLC-type controllers, which
inherently require attachment to other items of equipment and to a
BAS or other local computer network. Unlike PLC controllers, the
controller of the present invention is provided as a dedicated
standalone controller that can be accessed and controlled directly
either: locally, such as by user input through the connected local
display screen; or, remotely, such as by user input through an
Internet browser pointed to the website address and web page of the
controller. Using either access mode, and depending upon the level
of access authority provided to the user in the controller, the
user can be provided with direct and full access to the controller,
such as to review and make changes to equipment settings, to
acknowledge and reset events and alarms, and to perform any other
function required to monitor and control the connected
equipment.
[0025] A significant feature of the controller is its ability to
permit individual users to select the display parameters of the
displayed data. By way of non-limiting example, through drop-down
menus generated and provided by software executed by the
microprocessor of the controller, each individual user can select
the displayed units of measure, language of text, and other
features in a way that is most advantageous for them. For example,
the controlled equipment may be physically located in China. When
the local Chinese user is having an issue with the equipment, and
needs help, he or she calls a service technician, who may be in
Denmark. Depending upon the nature of the equipment issue, the
Danish service technician may require factory help, and therefore
calls the factory in the United States. While the parties are
speaking on the telephone, all three parties can access the webpage
of the controller simultaneously--the local user through the local
display screen, and the Danish and United States users through
devices having browsers pointed to the web page of the controller.
Each user accesses the webpage and provides a user identifier such
as a user name and password. The software of the controller
recognizes the user and retrieves a user profile or user access
level that includes the user's preferred display parameters. For
example, the Chinese user may have a low-level access level that
only permits viewing of displayed data, but no control. The Chinese
user's profile can further indicate the user's preference to
display data in Chinese, using metric units for all displayed
measurements. The software of the controller then converts the
generated data to meet the Chinese user's profile, and to display
the data on the Chinese technician's (local) display in Chinese
using metric units for all displayed measurements. By contrast, the
Danish user may have a higher access level with edit and control
capability that permits the Danish user to remotely control the
connected equipment. Additionally, the Danish user's profile
requires that the data displayed on the Danish user's remote screen
be shown in Danish and in metric units of measure. Lastly, the
United States user's access level permits high-level access for
such tasks as rewriting and rebooting of software of the
controller, and the United States user's profile can be set to
require display of all data in English, with English units of
measure. In this example, the end result is that the web server of
the controller, through the use of CGI scripts, sends HTML web
pages, as follows, to the various displays: to the local display
with the text in Chinese with pressure units in KPAA and
temperature in degrees Celsius ("C"); remotely to the Denmark user
with the text in Danish and pressure is BAR and temperature in
degrees C.; and finally to the remote United States user with text
in English and showing units of PSI and Fahrenheit.
[0026] Additional features of the invention are described
hereinafter with reference to a first preferred embodiment. In the
preferred embodiment, the controller is a controller for a
compressor of a refrigeration or HVAC&R system, and the
monitored operational parameters of the compressor include:
capacity slide position, volume slide position, suction pressure,
discharge pressure, oil pressure, main oil injection pressure,
economizer pressure, filter pressure, intermediate pressure (at an
intermediate stage of compression), balance piston pressure, system
discharge pressure, suction temperature, discharge temperature, oil
temperature of the compressor, oil separator temperature,
process/brine temperature leaving, process/brine temperature
entering, motor current, motor amps, motor and compressor speed
(RPM), compressor vibration during suction, compressor vibration
during discharge, motor vibration at a shaft side, motor vibration
at an opposite shaft side, and combinations thereof. However, other
parameters of HVAC&R compressors and other equipment can
additionally or alternatively be monitored, and the controller of
the invention can be used in conjunction with other HVAC&R
components and building equipment such as elevators, escalators,
fire systems, ingress and egress systems, and the like.
[0027] In the preferred embodiment of a controller for an
HVAC&R system including a compressor, the controller is part of
a control panel including a controller board and a local HMI, and
can be configured in any of several ways. Preferably, the
controller includes a local HMI having a graphics display, and is
located on or in close proximity to each controlled compressor.
Alternatively, the configuration can be comprised of several
controllers sharing a common local HMI. The controller board's
function is primarily to control and maintain the safe operation of
the compressor. At the same time, the controller delivers data to
the HMI for display, and accepts data input from a user of the HMI
for adjustment of HVAC&R system parameters, and for
configuration or reconfiguration of the system and all monitored
parameters thereof. For example, local display and set point
manipulation by a user is provided through the control panel,
preferably through input on a keypad and with graphic confirmation
and display of adjusted parameters and associated data.
[0028] The HMI's primary function is to allow the user to display,
monitor and manage data gathered and processed by the
microprocessor of the controller. The HMI further provides
communication connectivity to the controller and networked
equipment, which may include sequencing of multiple controllers
(regardless of controller type), as well as displaying data and
providing keypad interfaces for local accessibility. The manner in
which data is transferred between the HMI and the microprocessor of
the controller is exemplary--the information in the controller and
the HMI are stored as electronic data files. The communication
protocol for passing the data between the controller microprocessor
and the HMI is File Transfer Protocol. The File Transfer Protocol
(also known as "FTP" is a robust, well tested, industry standard
protocol. Additionally, the common files the controller
microprocessor and the HMI share include data and map files.
[0029] Controller Overview--The arrangement shown in FIG. 1 shows
one proposed software and hardware layout for the controller in an
HVAC&R system. As shown in FIG. 1 and described further herein,
there are four controller tasks that run independently of each
other. The data and map files are loaded into memory connected to
the microprocessor of the controller on power up, and are shared
between the four tasks. For example, the microprocessor controller
will hold data in an integral database that can be accessed and
manipulated simultaneously by one or more of a task or user. As
data in the system changes, the data and map files may be updated
as needed. Security levels in the map file prevent the data file
from being modified unless that level of clearance has been
authorized.
[0030] TASK 1: Control--The Control task of FIG. 1 operates the
compressor and includes the safety functions. The control task
starts and stops the compressor and maintains the set point of the
system. This task also looks at the values in the data file and
makes decisions based on the programmed logic. If the conditions of
the compressor change, the values in the data file are modified.
The Control task is in charge of starting and stopping the
compressor in response to instructions obtained manually,
automatically, or remotely (from a external device i.e., computer
system or distributed control system. The Control task has at least
four control modes, with each control mode having a channel
selection. The selected channel corresponds to an analog input
channel. The analog channel is in turn used to load or unload the
compressor and associated equipment in order to maintain the
setpoints for preselected parameters such as pressure, temperature,
and speed. Each mode is therefore "universal," and the map file or
the HMI screen may limit the control mode and set points. A normal
operation mode and a scheduling mode can be included in any of the
universal modes.
[0031] The safety controls are responsible for shutting the
compressor down in the event the safety operation of the machine is
compromised. The safety controls are responsible for stopping the
compressor from loading, force unloading of the compressor,
alarming when the compressor is nearing a critical shutdown point,
and performing shutdowns when the critical point is passed. These
safety controls are preferably made up of stop load points, force
unload points, alarm points, and shutdown points. Preferably, there
are about 50 safety point sets that can be set and monitored by the
controller. The control task will preferably define the majority of
the safety point sets based upon specification data received from
the connected HVAC&R equipment, although the set points can
alternatively be input by the user. Additionally, controller
preferably allows a user to manually create, edit, and delete set
points. This allows the user to customize the points of safety that
they feel are necessary for their application.
[0032] An Alarm/Shutdown history file is provided having multiple
monitored parameters, and the capability of creating and saving any
data that falls outside of preset ranges for those parameters as
alarm events. An exemplary listing of alarm events for a controller
of the present invention monitoring and controlling an industrial
compressor in an HVAC&R system follows:
[0033] Analog Board Comm. Fail--Shutdown--The software of the
controller is no longer able to communicate to a connected analog
board.
[0034] Analog Board Fail--Shutdown--The software of the controller
is no longer able to communicate to a connected analog board.
[0035] Auxiliary alarms--The auxiliary input module has been setup
to indicate an alarm when it is de-energized and it became
de-energized.
[0036] Auxiliary shutdown--The auxiliary input module has been
setup to indicate a shutdown when it is de-energized and it became
de-energized.
[0037] Balance Piston Failure Shutdown--Balance piston control is
usually enabled in initial setup. In the preferred embodiment,
there are three (3) conditions that will cause a Balance Piston
Failure Shutdown/alarm: 1) If the difference between discharge
pressure and suction pressure is less than 60 lb. and the balance
piston output module is de-energized, then the balance piston
pressure must be 1.1 times suction pressure plus or minus 15 lb.;
2) If the difference of discharge pressure and suction pressure is
greater than or equal to 60 lb. and the balance piston output
module (digital output module 12) is de-energized, then the balance
piston pressure must be 50 lb. below discharge pressure plus or
minus 15 lb.; 3) If the balance piston output module (digital
output module 12) is energized, then balance piston pressure must
be within 20 lb. of oil pressure.
[0038] Compressor Aux. Failure--This shutdown message is issued if
while the compressor is running, the compressor auxiliary input
module, which receives feedback from the motor starter, becomes
de-energized.
[0039] Compressor Interlock Failure--This shutdown message is
issued if while the compressor is running the compressor auxiliary
input module becomes de-energized for a predetermined time,
preferably about 5 seconds.
[0040] Compressor Starting Failure--Aux.--This shutdown message is
displayed if after about 30 seconds from sending the compressor
start command, the compressor auxiliary input module is still not
energized.
[0041] Compressor Starting Failure--Low Motor Amps--This shutdown
message is displayed if after about 30 seconds from sending the
compressor start signal, the motor amps reading is not greater than
the low motor amps shutdown set point.
[0042] Compressor Stopping Failure--Aux.--This shutdown message is
issued if while stopping the compressor, after about 5-10 seconds
from the compressor stop command, the compressor auxiliary is
energized. While this condition is present, the oil pump (if
available) is on and liquid injection (if available) is allowed on
and the slide valve is unloaded to 0% to safeguard the
compressor.
[0043] Compressor Stopping Failure--Motor Amps--This shutdown
message is issued if while stopping the compressor, after about
10-12 seconds from the compressor stop command the motor current
reading is above the low motor amps shutdown set point. While this
condition is present, the oil pump (if available) is on, and liquid
injection (if available) is allowed on and the slide valve is
unloaded to 0% to safeguard the compressor.
[0044] Compressor Unable to Unload--Alarm--While stopping the
compressor or the compressor is off, the slide valve position has
not unloaded below the highest slide valve position to allow
starting the compressor set point.
[0045] DBS Alarm--The RAM DBS (Digital Bypass Starter) Motor
Starter is responding that it has an alarm condition.
[0046] DBS Trip--The RAM DBS motor starter is responding that it
has a shutdown condition.
[0047] Digital Board Reset--Shutdown--If a reset of a digital board
occurs, a shutdown will result to prevent the motor from
restarting.
[0048] Digital Board Comm. Fail--Shutdown--It has been detected
that the program is no longer able to communicate to a digital
board of the controller.
[0049] Discharge End Compressor Vibration Alarm--If a discharge end
compressor vibration sensor registers a reading that is higher than
the value that has been set for the discharge end compressor
vibration alarm, for the period of time as set for the discharge
end compressor vibration alarm delay, an alarm will be
generated.
[0050] Discharge End Compressor Vibration Shutdown--If the
discharge end compressor vibration sensor registers a reading that
is higher than the value that has been set for the discharge end
compressor vibration shutdown, for the period of time as set for
the discharge end compressor vibration shutdown delay, a shutdown
will be generated.
[0051] Discharge Pressure Sensor Fault--This shutdown message is
issued if the Discharge Pressure reading was out of range for its
sensor.
[0052] Discharge Temperature Saturation Alarm--This alarm applies
if superheat has been enabled. When running, an alarm will
preferably occur if the saturated Discharge Pressure plus set point
temperature is greater than the Discharge Temperature for the set
point time.
[0053] Discharge Temperature Saturation Shutdown--This Shutdown
applies if superheat has been enabled. When running, a shutdown
will occur if the saturated Discharge Pressure plus set point
temperature is greater than the Discharge Temperature for the set
point time.
[0054] Discharge Temperature Sensor Fault--This shutdown message is
issued if the Discharge Temperature reading was out of range for
its sensor.
[0055] False Start Failure--Aux.--This shutdown message is issued
if while the compressor is off the compressor auxiliary is
energized. While this condition is present, the oil pump (if
available) is on, and liquid (refrigerant) injection (if available)
is allowed on and the slide valve is unloaded to 0% to safeguard
the compressor.
[0056] False Start Failure--Motor Amps--This shutdown message is
issued if while the compressor is off, the motor current reading is
above the low motor amps shutdown set point. While this condition
is present, the oil pump (if available) is on, and liquid injection
(if available) is allowed on and the slide valve is unloaded to 0%
to safeguard the compressor.
[0057] High Auxiliary Analog Alarm--An auxiliary analog value was
greater than or equal to the high auxiliary analog alarm set point
for its time delay.
[0058] High Discharge Temperature Alarm--The Discharge Temperature
was greater than or equal to the High Discharge Temperature Alarm
set point for its time delay.
[0059] High Discharge Temperature Shutdown--The Discharge
Temperature was greater than or equal to the High Discharge
Temperature Shutdown set point for its time delay.
[0060] High Discharge Pressure Alarm--The Discharge Pressure was
greater than or equal to the active High Discharge Pressure Alarm
set point for its time delay.
[0061] High Discharge Pressure Shutdown--The Discharge Pressure was
greater than or equal to the active High Discharge Pressure
Shutdown set point for its time delay.
[0062] High Economizer Alarm--The returned value was greater than
or equal to the High Economizer alarm set point for its time
delay.
[0063] High Economizer Shutdown--The returned value was greater
than or equal to the High Economizer Shutdown set point for its
time delay.
[0064] High Entering Process Temperature Alarm--The Entering
Process Temperature was greater than or equal to the High Entering
Process Temperature Alarm set point for its time delay.
[0065] High Entering Process Temperature Shutdown--The Entering
Process Temperature was greater than or equal to the High Entering
Process Temperature Shutdown set point for its time delay.
[0066] High Liquid Level Shutdown--The corresponding input module
was de-energized.
[0067] High Manifold Pressure Alarm--This alarm applies if the
Engine Drive was enabled. When the Manifold Pressure exceeds this
set point, an alarm will occur.
[0068] High Manifold Pressure Shutdown--This shutdown applies if
the Engine Drive was enabled. When the Manifold Pressure exceeds
this set point, a shutdown will occur.
[0069] High Motor Current Alarm--The Motor Amps was greater than or
equal to the High Motor Amps Alarm set point for its time
delay.
[0070] High Motor Current Shutdown--The motor amps was greater than
or equal to the High Motor Amps Shutdown set point for its time
delay.
[0071] High Oil Filter Pressure Alarm--The Oil Filter Pressure was
greater than or equal to the High Filter Pressure Alarm set point
for its time delay.
[0072] High Oil Filter Pressure Shutdown--The Oil Filter Pressure
was greater than or equal to the High Filter Pressure Shutdown set
point for its time delay.
[0073] High Oil Temperature Alarm--The Oil Temperature was greater
than or equal to the High Oil Temperature Alarm set point for its
time delay.
[0074] High Oil Temperature Shutdown--The Oil Temperature was
greater than or equal to the High Oil Temperature Shutdown set
point for its time delay.
[0075] High RPM Alarm--This alarm applies if the Engine or Turbine
Drive was enabled. If the RPM's of the motor exceeds this set
point, an alarm will occur.
[0076] High RPM Shutdown--This shutdown applies if the Engine or
Turbine Drive was enabled. If the RPM's of the motor exceeds this
set point, a shutdown will occur,
[0077] High Suction Pressure Alarm--The Suction Pressure was
greater than or equal to the active High Suction Pressure Alarm set
point for its time delay.
[0078] High Suction Pressure Shutdown--The Suction Pressure was
greater than or equal to the active High Suction Pressure Shutdown
set point for its time delay.
[0079] Insufficient Main Oil Pressure Shutdown--The Slide Valve is
greater than 50% and the Oil Pressure (PSIA) is less than or equal
to the Suction Pressure (PSIA) multiplied by 1.5 and then added to
15.0.
[0080] Liquid Slug Alarm--This alarm is triggered off of a sudden
decrease in Discharge Temperature that is greater than the Liquid
Slug Alarm set point for a five (5) second period. That is, if the
Discharge Temperature is 130 degrees F., and the Liquid Slug Alarm
set point is 10 degrees F., then a sudden drop in Discharge
Temperature from 130 to 120 degrees F. within a five second period
will generate an alarm condition.
[0081] Liquid Slug Shutdown This shutdown is triggered off of a
sudden decrease in Discharge Temperature that is greater than the
Liquid Slug Shutdown set point for a five (5) second period. That
is, if the Discharge Temperature is 130 degrees F., and the Liquid
Slug Shutdown set point is 20 degrees F., then a sudden drop in
Discharge Temperature from 130 to 110 degrees F. within a five
second period will generate a shutdown condition.
[0082] Low Auxiliary Analog Alarm--The Auxiliary Analog value was
less than or equal to the low Auxiliary Analog #1 alarm set point
for its time delay.
[0083] Low Auxiliary Analog Shutdown--The Auxiliary Analog value
was less than or equal to the low Auxiliary Analog #1 shutdown set
point for its time delay.
[0084] Low Economizer Alarm--The returned value was less than or
equal to the low economizer alarm set point for its time delay.
[0085] Low Economizer Shutdown--The returned value was less than or
equal to the low economizer shutdown set point for its time
delay.
[0086] Low Entering Process Temperature Alarm--The Entering Process
Temperature was less than or equal to the Low Entering Process
Temperature Alarm set point for its time delay.
[0087] Low Entering Process Temperature Shutdown--The Entering
Process Temperature was less than or equal to the Low Entering
Process Temperature Shutdown set point for its time delay.
[0088] Low Main Oil Injection Pressure Shutdown--This shutdown can
occur if Oil Injection was enabled. The Oil Injection Pressure must
be greater than or equal the Suction Pressure times 1.5, plus the
set point to be in the safe condition, otherwise this shutdown will
occur.
[0089] Low Motor Current Shutdown--This shutdown message is issued
if, while the compressor was running, the Motor Amps reading was
less than or equal to the Low Motor Amps Shutdown set point.
[0090] Low Oil Pressure Alarm--The compressor was running. Either
the Oil Pressure of a running pump was less than or equal to the
Low Oil Pressure Alarm set point, or the Oil Pressure of a not
running pump was less than or equal to the Low Oil Pressure Alarm
set point for its time delay.
[0091] Low Oil Pressure Shutdown--The compressor was running.
Either the Oil Pressure of a running pump was less than or equal to
the Low Oil Pressure Shutdown set point, or the Oil Pressure of a
not running pump was less than or equal to the Low Oil Pressure
Shutdown set point for its time delay.
[0092] Low Oil Separator Temperature Alarm--The Oil Separator
Temperature was less than or equal to the Low Oil Separator
Temperature Alarm set point for its time delay.
[0093] Low Oil Separator Temperature Shutdown--The Oil Separator
Temperature was less than or equal to the Low Oil Separator
Temperature Alarm set point for its time delay.
[0094] Low Oil Temperature Alarm--The Oil Temperature was less than
or equal to the Low Oil Temperature Alarm set point for its time
delay.
[0095] Low Oil Temperature Shutdown--The Oil Temperature was less
than or equal to the Low Oil Temperature Shutdown set point for its
time delay.
[0096] Low Process Temperature Alarm--Process Temperature was the
active Capacity Control and the Process Temperature was less than
or equal to the Low Process Temperature Alarm set point for its
time delay. This Process Temperature is the Leaving Process
Temperature.
[0097] Low Process Temperature Shutdown--Process Temperature was
the active Capacity Control and the Process Temperature was less
than or equal to the Low Process Temperature Shutdown set point for
its time delay. This Process Temperature is the Leaving Process
Temperature.
[0098] Low RPM Alarm--This alarm applies if the Engine or Turbine
Drive was enabled. If the RPM's of the motor drops below this set
point, an alarm will occur.
[0099] Low RPM Shutdown--This shutdown applies if the Engine or
Turbine Drive was enabled. If the RPM's of the motor drops below
this set point, a shutdown will occur.
[0100] Low Suction Pressure Alarm--The Suction Pressure was less
than or equal to the active Low Suction Pressure Alarm set point
for its time delay.
[0101] Low Suction Pressure Shutdown--The Suction Pressure was less
than or equal to the active Low Suction Pressure Shutdown set point
for its time delay.
[0102] Maintenance--Alarm--This alarm is generated from the
Maintenance Schedule. It indicates that the amount of hours in the
Service Every column has been exceeded. The alarm name may be
custom named by the operator. This is purely an informational
maintenance alarm, and there is no shutdown associated it.
[0103] Missing Oil Pressure Alarm--The Oil Pressure (PSIA) is less
than the Suction Pressure (PSIA) multiplied by 1.1 and then added
to 15.0, then delayed by 25 sec.
[0104] Missing Oil Pressure Shutdown 1--The Oil Pressure (PSIA) is
less than the Suction Pressure (PSIA) multiplied by 1.1 and then
added to 15.0, then delayed by 2 min.
[0105] Missing Oil Pressure Shutdown 2--The Oil Pressure (PSIA) is
less than the Suction Pressure (PSIA) added to 15.0, then delayed
by 25 sec.
[0106] Motor Stator Temp. Alarm--If Motor Stator temperature sensor
registers a reading that is higher than the value that has been set
for the Motor Stator Temp. Alarm, for the period of time as set for
the Motor Stator Temp. Alarm Delay, an alarm will be generated.
[0107] Motor Stator #1 Shutdown Alarm--If Motor Stator temperature
sensor registers a reading that is higher than the value that has
been set for the Motor Stator Temp. Shutdown, for the period of
time as set for the Motor Stator Temp. Shutdown Delay, a shutdown
will be generated.
[0108] Motor Starter Comm. Fail--Shutdown--It has been detected
that the program is no longer able to communicate to a RAM DBS
Motor Starter.
[0109] Oil Level Shutdown--The corresponding input module for low
Oil Level was de-energized for five (5) minutes.
[0110] Oil Log Shutdown--Oil log was enabled in Factory Setup and
the Compressor has not started and the Oil Pump has already run for
the fail delay time.
[0111] Oil Pressure Sensor Fault--This shutdown message is issued
if the Oil Pressure reading was out of range for its sensor.
[0112] Oil Pump Aux Failure--While starting the Oil Pump, the Oil
Pump Auxiliary input module did not energize within five (5)
seconds, or, while the Oil Pump was running, the Oil Pump Auxiliary
input module de-energized.
[0113] Oil Pump #1 Aux. Alarm--While starting Oil Pump #1, the Oil
Pump #1 Auxiliary input module did not energize within five (5)
seconds, or, while this Oil Pump was running, the Oil Pump #1
Auxiliary input module de-energized. This indicates Dual Pump
Control and Pump #1 is the lead pump.
[0114] Oil Pump #1 Aux. Failure Shutdown--While starting Oil Pump
#1, the Oil Pump #1 Auxiliary input module did not energize within
five (5) seconds, or, while this Oil Pump was running, the Oil Pump
#1 Auxiliary input module de-energized. This indicates Dual Pump
Control and Pump #1 is the last pump to start.
[0115] Oil Pump #2 Aux. Alarm--While starting Oil Pump #2, the Oil
Pump #2 Auxiliary input module did not energize within five (5)
seconds, or, while this Oil Pump was running the Oil Pump #2
Auxiliary input module de-energized. This indicates Dual Pump
Control and Pump #2 is the lead pump.
[0116] Oil Pump #2 Aux. Failure Shutdown--While starting Oil Pump
#2, the Oil Pump auxiliary input module did not energize within
five (5) seconds, or, while the Oil Pump was running, the Oil Pump
auxiliary input module de-energized. This indicates Dual Pump
Control and Pump #2 is the last pump to start.
[0117] Oil Temperature Sensor Fault--This shutdown message is
issued if the Oil Temperature reading was out of range for its
sensor.
[0118] Opposite Shaft Side Drive Vibration Alarm--If the Opposite
Shaft Side Drive Vibration sensor registers a reading that is
higher than the value that has been set for the Opposite Shaft Side
Drive Vibration Alarm, for the period of time as set for the
Opposite Shaft Side Drive Vibration Alarm Delay, an alarm will be
generated.
[0119] Opposite Shaft Side Drive Vibration Shutdown--If the
Opposite Shaft Side Drive Vibration sensor registers a reading that
is higher than the value that has been set for the Opposite Shaft
Side Drive Vibration Shutdown, for the period of time as set for
the Opposite Shaft Side Drive Vibration Shutdown Delay, a shutdown
will be generated.
[0120] Opposite Shaft Side Drive Temp. Alarm--If the Opposite Shaft
Side Drive Temperature sensor registers a reading that is higher
than the value that has been set for the Opposite Shaft Side Drive
Temperature Alarm, for the period of time as set for the Opposite
Shaft Side Drive Temperature Alarm Delay, an alarm will be
generated.
[0121] Opposite Shaft Side Drive Temp. Shutdown--If the Opposite
Shaft Side Drive Temperature sensor registers a reading that is
higher than the value that has been set for the Opposite Shaft Side
Drive Temperature Shutdown, for the period of time as set for the
Opposite Shaft Side Drive Temperature Shutdown Delay, a shutdown
will be generated.
[0122] Separator Temperature Sensor Fault--This shutdown message is
issued if the Oil Separator Temperature reading was out of range
for its sensor.
[0123] Shaft Side Drive Vibration Alarm--If the Shaft Side Drive
Vibration sensor registers a reading that is higher than the value
that has been set for the Shaft Side Drive Vibration Alarm, for the
period of time as set for the Shaft Side Drive Vibration Alarm
Delay, an alarm will be generated.
[0124] Shaft Side Drive Vibration Shutdown--If the Shaft Side Drive
Vibration sensor registers a reading that is higher than the value
that has been set for the Shaft Side Drive Vibration Shutdown, for
the period of time as set for the Shaft Side Drive Vibration
Shutdown Delay, a shutdown will be generated.
[0125] Shaft Side Drive Temp. Alarm--If the Shaft Side Drive
Temperature sensor registers a reading that is higher than the
value that has been set for the Shaft Side Drive Temperature Alarm,
for the period of time as set for the Shaft Side Drive Temperature
Alarm Delay, an alarm will be generated.
[0126] Shaft Side Drive Temp. Shutdown--If the Shaft Side Drive
Temperature sensor registers a reading that is higher than the
value that has been set for the Shaft Side Drive Temperature
Shutdown, for the period of time as set for the Shaft Side Drive
Temperature Shutdown Delay, a shutdown will be generated.
[0127] Starting Failure--This message may be issued if Engine or
Turbine was enabled, and the start delay period to get to a running
condition has expired.
[0128] Starting Superheat Shutdown--This message may be issued if
Superheat was enabled. A shutdown will occur if the saturated
Discharge Pressure plus temperature set point is greater than the
Separator temperature.
[0129] Suction End Compressor Vibration Alarm--If the Suction End
Compressor Vibration sensor registers a reading that is higher than
the value that has been set for the Suction End Compressor
Vibration Alarm, for the period of time as set for the Suction End
Compressor Vibration Alarm Delay, an alarm will be generated.
[0130] Suction End Compressor Vibration Shutdown--If the Suction
End Compressor Vibration sensor registers a reading that is higher
than the value that has been set for the Suction End Compressor
Vibration Shutdown, for the period of time as set for the Suction
End Compressor Vibration Shutdown Delay, a shutdown will be
generated.
[0131] Suction Pressure Sensor Fault--This shutdown message is
issued if the Suction Pressure reading was out of range for its
sensor.
[0132] Variable Speed Communications Alarm--If a variable speed
option is enabled and the Comms communication has failed, this
alarm is shown.
[0133] When the Control task detects monitored data falling outside
of the preselected range, an alarm event will be created. This
event stores the name of the alarm along with the specific time and
date the alarm was triggered. In a monitored compressor, for
example, at the same time the alarm event occurs, a set of
operating values are saved to record the compressor's condition at
the time of the alarm. This set of values is preferably defined by
the user, and the user-created value set or definition is stored in
an Alarm/Shutdown map file. As each alarm or shutdown is triggered,
the alarm event and the current operating values are saved to the
Alarm/Shutdown history file.
[0134] Preferably, there are a plurality of defined system timers,
such as 20 ten millisecond timers, 50 one-second timers, and 20
one-minute timers. The Control task is responsible for the
maintenance of the timers, but preferably a timer may be set by any
task. The timer is set by giving it a value greater than 0. The
Control task will then decrease the value of each timer according
to its delay type. When the timer reaches 0 it will stop
decrementing, and the timer will be inactive.
[0135] TASK 2: I/O Communications--The I/O Communications task of
FIG. 1 gathers sensor data from CAN bus, analog boards, digital
boards, and various Motor Starters/VFDs (variable frequency drive).
For example, by using a stored map file having preselected
formatting such as particular units of measure and other data
display preferences, the sensor data is preferably formatted to
degrees C. for Temperature and PASCALS for Pressure. Other sensors
for measuring parameters such as amps, compressor speed, and
acceleration can be formatted according to their sensor range as it
is defined in the map file. The formatted value is entered into its
appropriate location in the data file.
[0136] TASK 3: External Communications--External communications as
shown in FIG. 1 are divided into two functions. The first function
is serial communications with connected items such as building
equipment, RTU controllers, and PLC controllers, for example. Such
serial communications can use RS485, RS422, or RS232 standards. The
serial communications task supports basic control (stop, start,
load, unload, and status) for MODBUS, Allen-Bradley, and ACSII
protocols. The controller can be a slave in a legacy sequence
system, but the controller is not the master in sequencing other
controllers. The master feature will be performed through the
HMI.
[0137] The second external communications function, is responsible
for sending data to and from the HMI, and is preferably via a
provided Ethernet port of the controller. The protocol for sending
data files back and forth between the controller and a user
communicably connected to the controller by a HMI, is HTTP. The
data files sent by the controller provides the HMI with the data it
needs to display all the necessary information about the current
status of the compressor or other selected monitored equipment.
Preferably, there are four file types that can be sent: the
complete data file (including historical data), the map files, the
alarm history file, and an updated data file (which contains only
the modified data values). When the HMI requests the updated data
file, the External communications task looks at all updated data
values, creates a file, and sends it, but preferably does not store
it. The files that are then received back from the HMI are the
updated data file and the map files, which include any information
changed by the user.
[0138] TASK 4: Display and Keypad Functions--The final task of the
controller of FIG. 1 handles keypad and display functions of a
local HMI directly connected to the controller, such as a local
control panel preferably provided in the same housing as the
controller. This task preferably allows even the lowest level
access user to perform some basic set point adjustments and monitor
the controller. More preferably, only the most critical data is
displayed on the local HMI connected to the controller, such as
pressure and temperature of refrigerant at various compression
stages, as well as a few adjustable setpoints associated with those
parameters.
[0139] Human-Machine Interface (HMI)--FIG. 2 illustrates one
software layout for a locally connected HMI such as the local
control panel previously described. In this embodiment, the HMI not
only displays data as a local display, but also acts as a server by
distributing the data content to other connections via the Ethernet
port. In addition it is able to sequence compressors, deliver data
from the controller(s) to computer control systems and distributed
control systems, and perform real-time and history trends. These
responsibilities are preferably divided into at least four tasks
that run independently of one another, but that share the data and
map files of the controller.
[0140] TASK 1: Communications/Sequencing--The
Communications/Sequencing task of FIG. 2 controls the flow of data
from the controller to the HMI and from the HMI to the controller.
The task maintains the validity of the data by keeping the HMI's
data files up-to-date for a real time look and feel. It also sends
any new data input by an authorized user back to the controller.
For example, when a set point is changed the modified information
is sent back to the controller so the controller can update its
data file.
[0141] When the HMI is first powered on, it communicates with the
connected controller and polls for data and map files. After all
these files have been retrieved, the Communications/Sequencing task
will request the controller's modified data file on a periodic rate
that can be preset, or adjusted by a user. When any data value has
been changed, either by the user or by an HMI task, the HMI sends
its own modified data file back to the controller. The controller
in turn updates its own data files. In this way the information in
the controller and the HMI are kept in near-real-time sync at all
times.
[0142] TASK 2: Trending--The Trending task of FIG. 2 gathers data
from the controller (or any of various connected controllers) and
stores it in the HMI for local viewing as well as for sending
trending information to external devices and systems. Trending data
is maintained for both real time and history trends. The data for
each controller is gathered by a trending map file, which includes
the values to be trended. In this way trending can be setup
specifically for each controller. All data for trending will be
stored as a CSV (comma separated variable) file. This allows users
to import the trending data into reporting applications such as
computerized spreadsheets. The task is responsible for the
reporting of the data to the Web Server task. When a remote Web
user requests trending information, the web server passes the
specifics of the request to the Trending task. The Trending task
then generates the report from the trending data as an HTML file.
Finally the Web Server task serves the report to the user.
[0143] TASK 3: Web Server--The Web Server task of FIG. 2 is mainly
responsible for generating the HTML files that are sent to the
browser and/or to the local display as a user interface. There will
be a data file that is created for every connection. A connection
can be from the keyboard and screen located at the HMI or from a
remote PC. Each connection preferably has at least the following
four parameters: language, pressure units, temperature units, and
security level. This means that potentially a compressor in China
could be viewed at the same time by the local user in China, by a
person in Denmark, and by another person in the US. While the local
user in China is reading the data in Chinese, the individual in
Denmark could see the information in Danish, Bar, and .degree. C.
and the person in the US could view the same data in English, PSIG,
and .degree. F. The sever task takes the information in the data
file and the map files and by looking at the connection parameters
generates an HTML file to be displayed for that specific user. When
a set point change is attempted the range is checked against the
map file, and the user is informed that the input was invalid.
[0144] The system and methods of the present invention provide for
controlled access by users to avoid unauthorized receipt, review,
and editing of data, as well as unauthorized adjustment of
operating parameters of controlled equipment. Controlled access
includes the authorization of users, such as through user lists, as
well as the assignment of secure network identification numbers.
Authorized user or "buddy" lists, passwords, and other common
secure access features provided by known software and services can
be used to provide additional security. For example, software may
include a protocol for controlling the addition and deletion of
users, as well as authenticating users. In a preferred embodiment,
each controller and each authorized user has a unique
identification, and each item of building equipment and/or
controller has a secure address on a wide area network. The
identifications can be included in user lists created for
authorized users and stored in the controller or a component
communicably connected to a controller. Preferably, access to each
controller is password protected. In this embodiment, whenever the
web server is accessed by a user, the controller verifies the ID
and password provided by the requesting user against a stored list
of authorized identification numbers and passwords. Once verified,
the server allows access to data from the connected building
equipment.
[0145] Preferably, there are multiple levels of security provided.
In the preferred embodiment, users assigned a particular level of
security are not able to see the information that is inappropriate
for that level. More preferably, no data is grayed out or in any
way appear to be inaccessible--if the user cannot change it they
cannot see it. In one embodiment, five levels of user access
security are provided as follows: 1) Programming; 2) Factory; 3)
Service; 4) High level user; 5) General user.
[0146] In the preferred embodiment of an HTML-driven embedded,
non-PLC, controller system for the monitoring of equipment, the
equipment is a compressor of an HVAC&R system. The system can
be monitored by a local user using a local computer interface,
which preferably is in close physical proximity to the equipment,
and by a remotely located user using a remotely located interface.
The HVAC&R building equipment is communicably linked to a
controller having an embedded web server that is communicably
linked to a wide area network such as the Internet to permit
electronic signals and data from the building equipment to be sent
to a web page generated by the web server. The controller includes
a microprocessor and code (software) executable by the
microprocessor for data gathering, data conversion and formatting
data from the connected building equipment.
[0147] In the preferred embodiment of the system, the web server of
the controller is also communicably connected to a local data
network, preferably an Ethernet hub. The local data network may
include a local server, a local user interface device such as a PC,
laptop, PDA, or other computerized communication device, and a
gateway (that may be protected by a firewall) for connection to a
wide area network such as the Internet. The gateway is preferably
the same gateway incorporated in the controller and is controlled
by software residing on and executed by a microprocessor of the
controller. The wide area network is preferably the Internet, but
can be any suitable computer network.
[0148] Preferably, the web server of the controller includes a
gateway for direct connection to the wide area network, obviating
the need for a gateway in any connected BAS or local area network.
Local and remote users access the website through a user interface
device such as a PC, laptop, PDA, or other computerized
communication device that can access the wide area network. The
gateway of the embedded web server of the controller is preferably
firewall protected. The web server thus enables Internet-based
communication between a remote user (or local user) and the
controller.
[0149] The web server and controller act together to control the
access of local and remotely located users to data gathered from
each unit of building equipment connected to the controller. The
controller can preferably simultaneously connect to multiple items
of building equipment, it being understood that the number of
equipment devices supported by controller depends on configuration
of the controller.
[0150] Other system controllers includes a microprocessor executing
software to scan or poll the connected equipment to gather
equipment information. In the case of heating, ventilation, air
conditioning, and refrigeration (HVAC&R) building equipment,
the equipment information can include alarms and faults,
operational status (such as on, off, standby), mode and settings
(cooling, heating, fan only, selected temperature), operational
parameters (such as compressor speed, fan speed, thermostat
setting, refrigerant level, temperature and pressure), and
historical parameters (run time, downtime, maintenance), and other
data relevant to the connected equipment. Preferably, the scanning
or polling is automatically performed by the controller at least
once every five seconds. However, the intervals of time between
polling may be selected or altered by users, system administrators,
or other authorized personnel to a desired or appropriate time
period.
[0151] Depending upon the type of building equipment, data from the
building equipment may require conversion or formatting to make it
suitable for display. Preferably, the microprocessor of the
controller executes all necessary data conversion and/or formatting
to enable transmission and display of gathered data.
[0152] The invention further provides for methods of monitoring and
controlling building equipment using the HTML-driven embedded
controller. The controller automatically polls the connected
building equipment at preselected intervals and gathers alarms,
faults, and other preselected status data. More preferably, the
controller automatically polls only for analog and digital status
data such as faults and alarms. In the next step, the gathered data
is incorporated into CGI scripts by the microprocessor of the
controller. In the next step, the CGI scripts populate tags
provided in an HTML web page served by the web server. In the next
step, remote users log on to the web server using a remote
interface, and enter their user name and password. In the next
step, the software of the microprocessor of the controller
recognizes the user name and password and associates it with a
stored user profile that includes an access level for the
recognized user. In the next step, the server sends data to the
remote user's interface that corresponds with the user's access
level, along with computerized instructions executable by the
remote device for generating a display having the display
characteristics in the user's stored user profile. In the next
step, the remote user's interface displays the data, preferably in
numeric, tabular, and graphic display formats.
[0153] Notably, the features of the described embodiments of the
methods of the present invention can be combined to permit
automatic notification of alarms, faults, shutdowns, and other
critical operating parameters of the building equipment to
logged-on users, while also allowing remote users to select,
request, and obtain data concerning specific operating parameters
of particular items of building equipment.
[0154] The invention may further include features to conserve
controller memory. For example, data gathered by the controller for
connected equipment can be overwritten when the equipment is next
polled. Alternatively, data may be automatically retained by a
controller or connected system component having storage capacity
for a preselected period of time or up to a preselected number
files. Preferably, the preselected period of time to retain data
and/or the preselected number of stored data files, can be adjusted
by system administrators, local users, and remote users having an
appropriate access level. Lastly, data retrieved by a remote user
can be automatically deleted from any or all of the components of
the system when the next CGI script is transmitted to populate the
HTML web page.
[0155] While the invention has been described with reference to a
preferred embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
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