Fault-tolerant multi-node stage sequencer and method for energy systems

Information

  • Patent Grant
  • 6745085
  • Patent Number
    6,745,085
  • Date Filed
    Friday, December 15, 2000
    24 years ago
  • Date Issued
    Tuesday, June 1, 2004
    20 years ago
Abstract
A method for controlling energy systems such as multiple boiler systems to meet an energy need includes a controller configured as a sequencer with the remaining controllers act as individual boiler controllers which periodically send status messages to the sequencer. The energy need is determined by measurements at the sequencer which maintains runtimes of the boilers. The sequencer periodically sends control commands to the boiler controllers to add or delete boilers. The control commands give consideration to the run times of the boilers.
Description




BACKGROUND OF THE INVENTION




The present invention relates generally to staged energy systems and particularly to analog staged energy systems with fault tolerant and transparent dynamic load distribution based on stage status and runtime. The present invention will be explained with reference to a boiler system that includes multiple boilers, however it will be understood that the invention is applicable to a variety of energy systems.




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. If there is not adequate heat available for a building, the notion of occupant comfort relating to heating and cooling could be compromised on a grand scale, including the entire building being serviced by the boiler heating system.




The specification of a single, large heating capacity boiler can satisfy the heating demand for the worst load conditions, which in cold climate Heating Ventilating and Air Conditioning (HVAC) applications would be defined as the “design temperature”. Typically, a very cold outside air temperature requires the full capacity of the boiler to provide heat for the building. However, the typical use of this load level would be limited to a total of less than 2% of the total year time. Design of smaller, but multiple boiler system can lead to a reduction of the “excess capacity” of the boiler system on a typical system from 40% to 4%, which represents significant operational savings, increased system efficiency, and improved heat system reliability. For example a lightly loaded system could have its requirements met by using only 1 of 3 smaller, more efficient boilers instead of using ⅓ the capacity of a larger boiler.




The control system for a multiple boiler or staged boiler system is necessarily different from the control system for a single boiler. For example, in a multiple boiler system, consideration must be given to the number of stages, whether the boilers have variable firing rates, under what conditions an individual boiler will be turned on or turned off, the strategy for equalizing run time of the individual boilers, what occurs in the event of the failure of an individual boiler and other factors. In the past these considerations have frequently required a more or less custom design and installation process and the increased costs that accompany such a process.




Flame safety boiler controls directly affect elements that may cause an unsafe condition. Flame safety controls have very high safety standards, and require strict testing and failure analysis. 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. The use of staged boiler systems doe not affect the flame safety controls which are fully operational when staged boiler control systems are utilized.




Thus there is a need for a boiler control system that takes into consideration the number of boiler stages and whether the boilers have a variable firing rate, provides a technique for decisions as to firing rate or adding or deleting a boiler, equalizes run times and automatically compensates in the event of failure of an individual boiler.




Thus a need exists for a low-cost high-performance sequencing controller for use with multiple boiler systems and other multiple unit energy systems.




SUMMARY OF THE INVENTION




The present invention solves these and other needs by providing a method for controlling energy systems such as multiple boiler systems to meet an energy need. In one aspect 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 and the efficiency of operating an alternate number of boilers.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a diagram of a single boiler arrangement.





FIG. 2

is a functional block diagram of a Boiler Interface Controller (BIC) according to the principles of that invention.





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 Sequencer according to the principles of the HIP invention.





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. 7



a


and

FIG. 7



b


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. 9



a


is a flowchart illustrating the operation of the BIC invention in the water flow evaluation mode, mode


1


.





FIG. 9



b


is a flowchart illustrating the operation of the BIC invention in the water flow failure mode, mode


1


A.





FIG. 9



c


is a flowchart illustrating the operation of the BIC invention in a water flow test routine, T


1


.





FIG. 10



a


is a flowchart illustrating the operation of the BIC invention in the low gas pressure evaluation mode, mode


2


.





FIG. 10



b


is a flowchart illustrating the operation of the BIC invention in the low gas pressure failure mode, mode


2


A.





FIG. 10



c


is a flowchart illustrating the operation of the BIC invention in a low gas pressure test routine, T


2


.





FIG. 11



a


is a flowchart illustrating the operation of the BIC invention in the low air evaluation mode, mode


3


.





FIG. 11



b


is a flowchart illustrating the operation of the BIC invention in the low air failure mode, mode


3


A.





FIG. 11



c


is a flowchart illustrating the operation of the BIC invention in a low air test routine, T


4


.





FIG. 12



a


is a flowchart illustrating the operation of the BIC invention in the blocked drain evaluation mode, mode


4


.





FIG. 12



b


is a flowchart illustrating the operation of the BIC invention in the blocked drain failure mode, mode


4


A.





FIG. 12



c


is a flowchart illustrating the operation of the BIC invention in a blocked drain test routine, T


4


.





FIG. 13



a


is a flowchart illustrating the operation of the BIC invention in the prepurge evaluation mode, mode


5


.





FIG. 13



b


is a flowchart illustrating the operation of the BIC invention in the soft lockout mode, mode


5


A.





FIG. 14



a


is a flowchart illustrating the operation of the BIC invention in the ignition evaluation mode, mode


6


.





FIG. 14



b


is a flowchart illustrating the operation of the BIC invention in the flame failure mode, mode


6


A.





FIG. 14



c


is a flowchart illustrating the operation of the BIC invention in a flame failure test routine, T


5


.





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


9


A.





FIG. 18

is a flowchart illustrating the operation of the BIC invention in the post purge mode, mode


9


B.





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. 20



a


through


20




d


are flowcharts illustrating a portion of the operation of the HIP invention of

FIGS. 3 and 4

.





FIG. 21

is an example of a menu for an operator interface according to the prior art.





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 single boiler arrangement is shown in

FIG. 1

including water circulating pump


12


, primary heat exchanger


14


and secondary heat exchanger


16


which utilizes combustion waste heat


17


. Recirculating valve


20


insures that a minimum water temperature is maintained in the boiler. Supply or outlet water temperature sensor


22


, return or inlet water temperature sensor


24


, and bypass water temperature sensor


26


are also shown. A variable firing rate is provided for the boiler by variable frequency drive (VFD) combustion/purge blower


18


. Other techniques for providing a variable firing rate could be used.




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.




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 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. Typically the application generated by the LonBuilder Development software environment is compiled and stored in the custom EPROM for use by the node during execution. Certainly other microprocessors may be employed, but the programming will have to be appropriately modified.




Various control modules are 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


.




BIC


10


provides a request for heat signal


52


to flame safety controller


30


through boiler safety devices but BIC


10


does not perform flame safety functions. While BIC


10


does not perform flame safety functions, it does receive status information from boiler safety switches


66


and other devices. Typical safety switches relate to proving water flow is present, supply gas pressure is not too high or too low, combustion purge pressure is not to high or too low and a condensate drain is not blocked. These boiler safety status signals may be provided by an auxiliary contact (not shown) for each of contact closures


66


related to each of the four (4) safety switches. Safety switch status signals would be provided on conductors


68


. The order in which such auxiliary contacts are electrically connected is to be coordinated with the order of the modes described herein. 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


. As an alternative, 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.




The operation of BIC


10


is best understood by reference to the state diagram shown in

FIG. 7



a


and

FIG. 7



b


, which identifies the modes and transitions between modes and then by reference to a flowchart that provides the details of a specific mode. In general, 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.




In the preferred embodiment, 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. 7



a


and


7




b


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


1


. With reference to

FIG. 7



a


, 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


1


A, 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


1


A: If the call for heat is off, then initiate transition


7


-


20


to mode


0


. If the Low Water flow input returns to off, then initiate transition


7


-


22


to Mode


1


.




Transitions Out of Mode


2


: If the call for heat is off, then initiate transition


7


-


24


to mode


0


. If the Low Water Flow input is low, then initiate transition


7


-


26


to Mode


1


A. If The Gas Pressure Fail input is ON, then initiate transition


7


-


28


to mode


2


A Gas Pressure Fail. If the gas pressure fail input is off and all tests are complete, then initiate transition


7


-


30


to mode


3


, Air Pressure Evaluation.




Transitions Out of Mode


2


A: 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 initiate transition


7


-


38


to Mode


1


A. 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


4


A 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


1


A. If The Gas Pressure Fail input is on, then initiate transition


7


-


70


to mode


2


A. If the Low air input is on, then initiate transition


7


-


72


to mode


3


A. If Block drain input is on, then initiate transition


7


-


74


to Mode


4


A Block Drain. Refer to flowcharts for information on transition


7


-


76


to Mode


5


A, Soft Lockout and transition


7


-


78


to Mode


6


, Ignition Evaluation.




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


5


A, transition


7


-


92


to Mode


5


A, transition


7


-


90


to Mode


6


A, 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


1


A




Transitions Out of Mode


7


: Refer to flow charts for conditions for transition


7


-


100


to Mode


9


A, 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


9


A Post Purge Prepare.


8


A, 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


9


B, Post Purge.




Transitions Out of Mode


9


B: When Post Purge timer expires, initiate transition to Mode


0


, Idle.




By way of example, if no call for heat exists, then BIC


10


is in an “Idle” mode, mode


0


as illustrated in FIG.


8


. When a call for heat condition occurs, BIC


10


selects a first evaluation mode within an ordered succession of evaluation modes. In the preferred form, the first evaluation mode is the Water Flow Evaluation, mode


1


as illustrated in

FIG. 9



a


. The water flow evaluation mode may result in BIC


10


returning to the Idle mode if a call for heat no longer exists, or initiating a next evaluation mode, i.e., the Gas Pressure Evaluation, mode


2


as illustrated in the

FIG. 10



a


. In the event that water flow is not proven in mode


1


, then a water flow failure mode, mode


1


A as shown in

FIG. 9



b


is initiated. Mode


1


A 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. An understanding of the other modes may be had by reference to the appropriate flowcharts.




A particular embodiment of BIC


10


has been described and many variations are possible. By way of example, and not by way of limitation, BIC


10


is useful with boilers that employ a greater number or a lesser number of boiler safety switches, boilers that do not have a variable firing rate and boilers that are not condensing type boilers and therefore do not use the system bypass valve.




Although the BIC has adequate evidence for mode changes, it is not to be depended on for any flame safety control functions. However, the information that the BIC has will be highly useful information for performance evaluation and troubleshooting of boiler systems.




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.




The operation of 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.




A human interface panel (HIP) for use with BIC


10


is shown in the figures and generally designated


100


. HIP


100


will be explained by reference to its use with BIC


10


, but it is to be understood that the principles will be useful with any boiler system that is arranged to take advantage of the features of the HIP of the present invention. HIP


100


in a single boiler configuration with BIC


10


is illustrated in FIG.


3


. Where inputs to BIC


10


from sensors are designated with a reference numeral and a letter, e.g., return water temperature


24




a


indicating that a sensor for the same purpose was described with regard to FIG.


2


. Temperature control module


28




a


receives signal


36




a


from sensor


22




a


located in the boiler supply water, signal


38




a


from sensor


24




a


located in the boiler return water, and signal


44




a


from sensor


42




a


located in outdoor air. BIC


10


also provides for receiving a setpoint signal related to a desired control setpoint signal. Bypass temperature control module


32




a


receives signal


40




a


from bypass temperature sensor


26




a


and provides signal


46




a


to bypass valve


20




a.






HIP


100


in the preferred form includes arbitration logic module


102


having a number of status inputs that will be further explained, transceiver


106


and a command display device (CDD)


104


. According to the principles of the HIP invention, arbitration logic module


102


receives status inputs from BIC


10


and other status devices including boiler safety switch status


68




a


, ignition device status signal


70




a


, gas valve status signal


72




a


, combustion/purge fan status


64




a


, pump status


76




a


, flame safety controller status signal


78




a


, temperature control status


130


, bypass status


132


, and bypass resynch status


134


. For simplicity, only representative inputs to arbitration logic


102


have been shown in FIG.


3


. In operation, the arbitration logic is implemented by reading all inputs to arbitration logic module


102


including the following: request for heat, sys disable, sys init, emergency, factory test, high temp, freeze protect, hvac emerg, hvac off, water flow safety, gas pressure safety, high/low gas pressure safety, low air pressure safety, block drain safety, pre-purge, ignition ON, gas valve ON, flame fail, post-purge, sequencer, fire low, fire mid, fire hi, number of stages, total stages, staged firing rate, min firing timer.




After reading all inputs, arbitration logic


102


then processes the readings according to the structure shown in the flow chart of FIG.


20


. Arbitration logic module


102


provides output


108


to transceiver


106


which provides signal


110


to CDD


104


. Arbitration logic module


102


and transceiver


106


are located at the boiler and may be in the same enclosure as BIC


10


while CDD


104


may be located at a distance from the boiler. CDD


104


in the preferred form includes an Echelon transceiver


112


, Echelon Neuron 3120 processor


114


, microprocessor


116


, configuration memory


118


, memory


120


, keypad


122


and LCD screen display


124


. Neuron processor


114


periodically, e.g., once per sec, requests the status of a specific status variable using the address and identification of the device and status variable. Arbitration logic module


102


responds with arbitration encoded signal


110


which is received thru transducer


112


and stored in a communications buffer in Neuron processor


114


. Microprocessor


116


processes and decodes the message to user friendly text and buffers and displays the message on display


124


.




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. In addition 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. Information on the use of the Lonworks System is available from the Echelon Corporation, 4015 Miranda Avenue, Palo Alto, Calif. 94304, USA. While certain specific embodiments of the present invention are described with reference to the LonWorks System, it is not intended that the invention be so limited. Other processors and communication protocols could be used.




The use of the HIP with a single boiler has been described. In addition, the HIP may be used in a multiple boiler system where a number of individual boilers are installed with the pumping and water piping arranged to provide for common system return water temperature, common system supply temperature and common system bypass temperature. The use of HIP


100


in a multiple boiler embodiment is illustrated in

FIG. 4

where BIC


1


interfaces to Boiler


1


and BIC X interfaces to Boiler X. The use of HIP


100


with multiple boilers includes the use a sequencing controller


200


, the operation of which is more completely described herein.




In the multiple boiler embodiment BIC


10


is configured with modules as shown in

FIG. 4

including system temperature control module


202


, outdoor air reset module


210


, analog stage control module


216


, stager module


204


, sequencer control module


222


, stage status module


224


, runtime mode stage control module


226


, pump controller


227


, system bypass control module


250


and network interface


228


. In operation, temperature control module


202


and stager module


204


both receive system return water temperature from sensor


206


and system supply temperature from sensor


208


. Outdoor air reset module


210


receives outdoor air temperature from sensor


212


and provides a reset setpoint to system temperature control module


202


. System temperature control module


202


provides request for heat signal


276


to pump controller


227


and, to arbitration logic module


102




a


as well as freeze protection signal


274


to arbitration logic module


102




a


. Analog stage control module


216


receives temperature control information signal


218


from and provides system firing rate signal


220


to sequencer control module


222


and to arbitration logic module


102




a


. Stager module


204


provides a requested number of stages signal


238


to sequencer control module


222


and to arbitration logic module


102




a


based on a rate of change of the temperature difference between the supply temperature


208


and return temperature


206


and other variables. Stage status module


224


receives information from BIC


1


and BIC X. System bypass control module


250


receives a system bypass temperature from sensor


252


and provides bypass status


256


and system resynch status


258


. Multiple boiler arbitration logic module


102




a


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


102




a


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.




In the preferred form, unique status modes are displayed as shown in Table 1. The term status mode or application mode may be used interchangeably. The meaning of the individual status modes will be apparent from the EnumType.














TABLE 1











Enum-






DataType bice.txt




EnumType




Value

























STATUS_MODE




START_UP_WAIT




0






STATUS_MODE




IDLE




1






STATUS_MODE




WATER_FLOW_EVAL




2






STATUS_MODE




AIR_PRES_EVAL




3






STATUS_MODE




BLOCK_DRAIN_EVAL




4






STATUS_MODE




LOW_GAS_PRESS_EVAL




5






STATUS_MODE




PRE_PURGE




6






STATUS_MODE




IGNITION_EVAL




7






STATUS_MODE




BOILER_ON_EVAL




8






STATUS_MODE




HEAT




9






STATUS_MODE




WATER_FLOW_FAIL_MODE




10






STATUS_MODE




AIR_PRESS_FAIL_MODE




11






STATUS_MODE




BLOCK_DRAIN_FAIL_MODE




12






STATUS_MODE




BLOCK_FLUE_FAIL_MODE




13






STATUS_MODE




LOW_GAS_PRESS_FAIL_MODE




14






STATUS_MODE




FLAME_FAILURE_MODE




15






STATUS_MODE




SOFT_LOCK_OUT_FAIL_MODE




16






STATUS_MODE




HEAT_MOD_FAIL_MODE




17






STATUS_MODE




MANUAL




18






STATUS_MODE




FACTORY_TEST




19






STATUS_MODE




PUMP_ONLY




20






STATUS_MODE




EMERGENCY_MODE




21






STATUS_MODE




DISABLED_MODE




22






STATUS_MODE




HIGH_TEMP_MODE




23






STATUS_MODE




OFF_MODE




24






STATUS_MODE




SMOKE_EMERGENCY




25






STATUS_MODE




POST_PURGE




26






STATUS_MODE




FREEZE_PROTECT_MODE




27






STATUS_MODE




POST_PURGE_PREPARE




28






STATUS_MODE




FLOAT_OUT_SYNC




29






STATUS_MODE




IDLE_MIN_DELAY




30






STATUS_MODE




SPARE_MODE2




31






STATUS_MODE




SEQ_HEAT_0STGS




32






STATUS_MODE




SEQ_HEAT_1STGS




33






STATUS_MODE




SEQ_HEAT_2STGS




34






STATUS_MODE




SEQ_HEAT_3STGS




35






STATUS_MODE




SEQ_HEAT_4STGS




36






STATUS_MODE




SEQ_HEAT_5STGS




37






STATUS_MODE




SEQ_HEAT_6STGS




38






STATUS_MODE




SEQ_HEAT_7STGS




39






STATUS_MODE




SEQ_HEAT_8STGS




40






STATUS_MODE




SEQ_HEAT_9STGS




41






STATUS_MODE




SEQ_HEAT_10STGS




42






STATUS_MODE




SEQ_HEAT_11STGS




43






STATUS_MODE




SEQ_HEAT_12STGS




44






STATUS_MODE




SEQ_HEAT_13STGS




45






STATUS_MODE




SEQ_HEAT_14STGS




46






STATUS_MODE




SEQ_HEAT_15STGS




47






STATUS_MODE




SEQ_HEAT_16STGS




48






STATUS_MODE




HEAT_LOW




49






STATUS_MODE




HEAT_MEDIUM




50






STATUS_MODE




HEAT_HIGH




51














The HIP boiler status display variable structure is shown in Table 2.


















TABLE 2












Example Data




Field





Field







Field Name




(Range)




Length




Data Type




Description





























NvoBoilerStatus




ApplicMode




HEAT




1 byte




ENUMERATION




Current






Share:





(See table 1





(BYTE)




Application






Polled From





for list of





of type




Mode of to be






Boiler to HIP or





Enumerations)





STATUS_MODE




commanded to






monitoring node








the boiler - See











Table 1 for











possible values







Additional




. . .




. . .




. . .




. . .







fields







Additional




. . .




. . .




. . .




. . .







fields














The HIP provides access to all control boiler functionality such as mode progression monitoring, pre-purge speed, pre-ignition speed control, Heat evaluation mode, and post purge ignition shutdown capabilities from the temperature control BIC. By proper boiler system design, all mode monitoring and transitions present in the BIC can be implemented without interfering with the flame-safety controller's safety requirements. In addition, the BIC provide temperature control of multiple stages of a high efficiency condensing, automatic bypass control, modulating firing rate boiler at both the individual modular boiler level and system sequencing level.




Now that the operation of HIP


100


has been set forth, many advantages can be further set forth and appreciated:




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. By making the status of the boiler modes and safety conditions readily available, safety is improved and the chance of injury due to boiler explosion is reduced. Safety and Health benefits are accrued though addition system incorporation into the HIP display.




Cost: 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. By using fewer relays to interface the information to traditionally expensive automation panels, and through the use of low cost displays, multiple display locations of boiler status results are possible.




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. Without the wide variety of wiring and remote connections, the design is much more durable than previous




Interoperability—Since the boiler system preferred implementation is performed on the Echelon LonWorks System, multi-vendor support, internet communication, cell phone access, and remote diagnostics, trending, database analysis, and support can be afforded through 3


rd


party solutions. By utilizing a non-flame safety device, the communications interface is removed from the failure recovery and acknowledgment mechanisms inherent in the protocol used for flame safety devices.




Convenience/Repair—by being aware of the operation and failure modes of the boiler, a repairperson would be able to save a trip or carry the correct part with them before making a service trip to the boiler installation. Careful inspection and monitoring of a boiler transition of the status modes, and observation of the conditions up to the failure can reveal the boiler operation condition with startling accuracy. The Hip and Boiler Interface units themselves are quite simple and lead to quick repair of failed units.




Efficiency: By observing the actual firing status and system operation, conclusions about the operational efficiency and number of stages required to achieve stable control of heat transfer can be observed directly in real time from a remote location. By detailed observation of the boiler status and sequence status selected, an efficiency comparison of operational savings of boiler operation can be observed and documented.




Precision: By observing timely, efficient updates of Boiler Modes and sequencing status, a precise view of the operation of the boiler can be achieve without requiring a separate trip to the boiler room.




Enhancements: Related products 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.




Although a separate state controller and flame safety control mechanism is presumed to already exist in the boiler flame safety controller, the best location for the logic is in the BIC temperature controller and sequencer, where access to open system communications, sequencing controls, temperature control, and programming schedule information resides. The BIC implementation allows for all of the invention's features described above.




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


102




a


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. Sequencer node


300


includes sequencer


302


, Runtime &Mode Stage Controller


304


, Stage Status Array


306


, temperature controller


308


, stager


310


, analog stage control


312


, mode controller


314


, and Network Interface


316


. In operation, temperature controller


308


provides firing rate temperature demand signal


320


to analog stage controller


312


and stage temperature demand signal


322


to stager


310


. Sequencer module


302


receives number of stages required signal


324


from stager


310


and provides sequencing information signal


326


to runtime and Mode stage controller


304


. Mode controller


314


receives temperature control status signal


328


and provides mode status signal


330


. Mode controller


314


provides mode status signal


332


to runtime and mode stage controller


304


and mode signal


334


to network interface


316


. 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


380


is an active communications and control node that interfaces to an active energy source. In the context of boiler systems, stage node


380


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


380


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. Though the use of the decision technique implemented in the runtime and mode stage controller, operations and total runtime hours from the modular stages are reflected in decisions to request control actions for the modular heat units in the system. This allows dynamic load balancing as problems affect single and multiple modular heating nodes.




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. By proper boiler system design, all mode monitoring and transitions present in the stage node can be implemented without interfering with the sequencer nodes staging requests. In addition, if any errors or faults occur in stage node


380


, then 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.




Referring to

FIG. 6

, periodically sequencer


200


broadcasts a nvoSeqShare message


286


globally to all the nodes, however each nvoSeqShare message is intended for a specific node address and the message contains this specific node address. Similarly all stage nodes broadcast their nvoModBoilerShare message


288


back to sequencer


200


where the message is decoded. 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













Values

















Percent heat stage




0 to 100%




Actual Heat % from stage






Heat stage runtime




0 to 65534 hrs.




Number of hours from stage






Heat stage add rank




0 to 16




See note 1






Heat stage del rank




0 to 16




See note 1











Note 1














Heat stage combination




Resultant Action






Add rank = !0, del rank = 0




Off Stage !0 means not 0






Add rank = 0, del rank = !0




On Stage !0 means not 0






Add rank = 0, del rank = 0




Stage disabled, Invalid or Offline






Add rank = !0, del rank = !0




Invalid, will be reset to add rank = 0 and







del rank = 0











Data structure


2


and data structure


3


are shown in tables 3 and 4 respectively.


















TABLE 3












Example Data




Field





Field







Field Name




(Range)




Length




Data Type




Description





























nvoSeqShare:




ShareTempHeat




45%




2 bytes




SIGNED LONG




Share






From




Cmd




(0 to 100%)






Temperature






Sequencer to








Heat Command-






Modular Boiler








Output






Nodes








Command of






(nviSeqShare)








heat to modular











boiler







ModularBlrID




 3




1 bytes




UNSIGNED




ID# of Mod










INTEGER




boiler for which











this command is











intended







ApplicMode




HEAT = 9




1 byte




ENUMERATION




Current








(See table 1





(BYTE)




Application








for list of





of type




Mode to be








Enumerations)





STATUS_MODE




commanded to











the boiler-See











Table 1 for











possible values







Stage Enable




ON = 1




1 byte




UNSIGNED INT




Stage











Enable/disable











command to be











commanded to











the boiler




























TABLE 4












Example Data




Field









Field Name




(Range)




Length




Data Type




Field Description





























NvoModBoiler-




BoilerMode




HEAT




1 byte




ENUMERATION




Current Application






Share:





(See table 1





(BYTE)




Mode of modular






From Modular





for list of






boiler. See Table 1






Boiler to





Enumerations)






for possible values






Sequencer




Stage Enable




ON, 100%




2 byte




SNVT_SWITCH




Stage Enable/disable






(nviModBoiler








command to be






share)








commanded to the











boiler







ModularBlrID




 3




1 bytes




UNSIGNED




ID# of Mod boiler for










INTEGER




which this command











is intended







ModBlrAlarm




ON




1 byte




ENUMERATION




Current Alarm Mode










(BYTE)




of the modular boiler.










of type




Enumeration to be










STATUS_MODE




defined customer for











boiler application







BoilLoad




45%




2 bytes




SIGNED LONG




Actual Mod Boiler








(0 to 100%)






firing rate-







BoilerRunTimeHr




250 hrs (0 to




2 bytes




UNSIGNED




Number of hours that








65535 hrs)





LONG




this modular boiler











stage has run.














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. It will be apparent that using the principles of the present invention, 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.




This invention has applications to analog staged energy systems with fault tolerant and transparent dynamic load distribution based on stage status and runtime.




While 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.




The self-configuration invention, an automatic self-configuration technique, will now be described. This technique acts in place of a network configuration tool such that it provides status and information to be transferred from client nodes back to a designated supervisory node so that proper operation can take place without the use of a configuration tool. This technique represents substantial value as a self-configuration technique for automatic node addressing and self-configuration for multi-node Supervisory/Client control systems. Referring to

FIG. 19

, a diagram illustrating self configuration technique


400


is shown including a supervisory node


402


, client node


404


, client node


406


, client node


408


and client node


410


. Additional details of the self-configuration invention are provided in Table 5. In general nvoClientID could replace the functionality of nvoSupvShare and assign the client nodes to a client ID.

















TABLE 5











Field Description




Example Data




Field Length




Data Type




























Network Variable




NID field [6]




00 01 5D 4F 11 26




6 bytes




HEX






nvoSupvShare:




ui Client Cmd S4




45%




2 bytes




UNSIGNED






from Supervisor




Client ID




3




1 byte




UNSIGNED






Controller to




applic Mode




HEAT




1 byte




ENUM of type






Client Nodes







STATUS_MODE






(assigns client




Effective Occ




Occ




1 byte




SNVT_OCCUPANCY






nodes to a client




Node Enable




ON




1 byte




ENUM






ID)






nvoClientShare:




Client Mode




HEAT




1 byte




ENUM






from Client to




Node Enable




ON




1 byte




ENUM






Supervisor




Client ID




3




1 byte




UNSIGNED






Controller




Effective Occ




Occ




1 byte




SNVT_OCCUPANCY







ALARM




ON




1 byte




ENUM







ui Client Load S4




44%




2 bytes




UNSIGNED






nvoClientID:




NID field [6]




00 01 5D 4F 11 26




6 bytes




HEX (OWN NID)






periodically




Client ID




3




1 byte




UNSIGNED














broadcast from





1 to FE




Client ID from Client to Supervisor






Client to





Ø→




sending from Supervisor (optional Ø to






Supervisor






FE) to Client






(broadcast client's






neuron ID for






collection by






supervisor)














This invention resides in the Node firmware portion of the control system and provides for binding of a 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.




2. Initially all nodes are pre-configured identically at the factory default values.




3. Initially nvoSupvShare of all nodes are bound to nviSupvShare of all nodes in a group, and nvoClientID of all nodes is bound to nviClientID of all nodes in a group




4. All nodes have the same domain/subnet/node addresses with the clone_domain-bit set




5. 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 CFG_LOCAL showing that no configuration tool has changed any configuration parameters.




6. Periodically (every 30 seconds) the individual client nodes broadcasts nvoClientID to the supervisory node nviClientID. Other clients also receive nviClientID but ignore nviClientID. NvoClientID contains nviClientID.NIDOut (a 6-character NID string) and the ClientIDOut 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 nviClientID information, but the Supervisory stores the nvoClientID information into and array and sorts them by NID (Neuron ID). For example:




Sequence Array [0].NID=00 OF 30 FF 1 C 00 Sequence Array [0].rank=1




Sequence Array [1].NID=00 OF 31 FF 1 C 00 Sequence Array [1].rank=3




Sequence Array [2].NID=00 OF 31 FF 1 F 00 Sequence Array [2] rank=2




Sequence Array [3].NID=00 FF 31 FF 1 F 00 Sequence Array [3] rank=4




8. Supervisory node


402


periodically broadcasts nvoSupvShare to nviSupvShare of all nodes. nvoSupvShare contains a field to identify the NID and its ClientID (the index of the array). The supervisory node receives nviSupvShare but ignores nviSupvShare. Client nodes respond to the nvoSupvShare broadcast if the NID matches their own Neuron ID (set in by the manufacturer of the neuron integrated circuit).




9. At the client node, if the NID matches its own node, the new ClientID will be updated to match the new ClientID assigned to it. This involves changing the Subnet/Node assignment also so that the Subnet is fixed to 1 and the Node is set to the same as the ClientID. From now on, when the client node broadcasts nvoClientID, the ClientID will use the ClientID assigned to it by the supervisory node.




10. Optionally, other feedback and status of the Client node is Broadcast (via nvoClientShare) back to the Supervisory node to give a positive ID status of the client ID, the Client state and the client analog value.




Control systems that utilize a number of client nodes with individual interfaces to the client controllers require a control system that provides for the coordination of the client nodes. Supervisory node


402


and the individual client Controllers


404


,


406


,


408


, and


410


must be configured so that communication can occur between supervisory node


402


and the individual clients.




All nodes in this invention are initially factory-configured as “clone-domain”, and Echelon LonWorks attribute indicating a special mode where unique subnet and nodes IDs are not necessary for communication, thus allowing a single configuration to be used to communicate to all other nodes through the same domain.




A single manufactured node type is allowed to be used in both the Supervisor and the individual client node identified as Client 1 to Client 16. Supervisory node


402


is self identified by means of a shorted configuration identification input, and client nodes


404


,


406


,


408


, and


410


are assumed identified by means of the lack of the presence of the shorted configuration identification input. The binding is simply three sets of network variables, called:




nvoClientID and nviClientID




nvoSupvShare and nviSupvShare




nvoClientShare and nviClientShare




Individual fields within the network variables are identified in Table 5.




Periodically, Each individual node nvoClientID is broadcast globally to all the nodes. All non-Supervisory nodes discard the message, but the supervisory node uses a predefined array to collect, rank and assign an individual boiler's unique identifier (called NID or Neuron ID). The unconfigured client node will broadcast a client ID of “00”. The Supervisory will broadcast a boiler ID of “FF.”




Internally, the Supervisory node's client number ranking is now broadcast (via nvoSupvShare) on the clone domain to all the nodes found, including itself. Only the client nodes are programmed to listen to the NID that matches its own node, and subsequently internalize the Client ID and optional analog value commands including mode, analog value, and occupancy status. The process of internalizing the client ID may include internal changes such as updating unique binding and configuration assignments associated with the client node.




Upon reception of the Client ID assignment for the node, the new nvoClientID from the client nodes will broadcast a client ID of “XX,” where XX represents the client ID number of that node.




Other feedback from the client node is broadcast (via nvoClientShare or nvoClientID) back to the Supervisory to give positive identification status of the Client ID, the Client State, and analog value.




The self-configuration technique of the present invention has applications to an unknown quantity Supervisory/Client node system to provide self-configured, automatic addressed, multi-stage-modulating control.




Another aspect of the Human Interface Panel


100


of the present invention involves the display of boiler status information on a menu level.




The traditional method of displaying user point information and grouping structures as shown in

FIG. 21

involves navigating a user menu with descriptions. The menus conform to a hierarchical directory structure with a menu structure of organization eventually ending in a selection that reveals point description and values on a multi-line text screen. For an example, a user at a text-based terminal could Select the Mechanical room menu


2


and receive a List of selections including Sequencer, Boiler #1, and Boiler #2. After selecting item 1-Sequencer, the point information for the sequencer, i.e., point information items 1-5, which relate only to the Sequencer would be displayed.




HIP


100


provides for displaying selective controller information in combination with the Menu choice of controller, for example Sequencer, Boiler #1, Boiler #2. The selective information from the controller is combined with the logical controller name information (Sequencer, Boiler #1, and Boiler #2) and results in a “concentration” of information from the associated boiler. To address the need for a low cost display, the point information must be relatively short (small number of characters) and must be able to be displayed in a short space, appropriate for a smaller LCD screen terminal device.




HIP


100


provides for combining information from a number of controllers. With reference to

FIG. 22

, where the controller name, Boiler #1 (available from the node variable for Boiler #1 as nciDevicename) is combined with the Boiler Status variable “nvoBoilerStatus.ApplicMode”. Optionally, the additional information from nvoFiringRate could be also included in the result.




For example, 2.ModBlr#01—Heat 17%




would be an aggregation of 3 parts:




the first part is the Boiler# 1 nciDevice name or boiler node name stored in the boiler interface controller which is “ModBlr#01”, the second part is the Boiler #1 nvoBoilerStatus.ApplicMode value which is “Heat”, and the third part is the Boiler #1 nvoData.firingRate value which is 17%.




The nvoBoilerStatus data Structure is shown in Table 6.


















TABLE 6












Example Data




Field









Field Name




(Range)




Length




Data Type




Field Description





























NvoBoilerStatus:




ApplicMode




HEAT




1 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







Additional




. . .




. . .




. . .




. . .







fields







Additional




. . .




. . .




. . .




. . .







fields














Each choice of the Sequencer, Boiler #1, and Boiler #2 represent point information from different controllers. The 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.




As implemented in HIP


100


, 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:




Line 1. Sequencer—Heat2Stg-33% . . .




In this example, a Sequencer is sequencing 3 modular boilers. The Sequencer menu displays the Sequencer Status mode in the Heat producing stage, requesting 2 modular boiler for heat with a total system demand of 33% of capacity:




Line 2. ModBlr#01—Heat17%




The sequencer is requesting Boiler #2 to produce heat at 17% of capacity and is functioning normally in the Heat Mode.




Line 3. ModBlr#02—LoGasFail 0%




Modular Boiler #2 is being requested to produce heat by the sequencer, however due to a low gas pressure condition, the boiler is not firing. The firing rate is 0% due to the failure mode. If the HIP operator was knowledgeable about the system firing rate request information, the user could have noticed that the system request is for 33% firing rate, and the first stage is request 17%, leaving 16% load for the 2


nd


stage.




Line 4 ModBlr#03—Idle 0%




The Sequencer is not requesting this stage to produce heat, and this stage is off. It is active and has no problems, so it is in the “idle” mode waiting for a request for heat signal from the sequencer.




The Boiler repair person could view the system level view just described and take additional steps such as the following: verify that the gas supply is available; call the gas company to see if the gas supply to that boiler has been turned off; and perform or view other diagnostic information before traveling to the boiler location.




The information and organization of this rich content menu system for boilers results in reduce troubleshooting time, additional operation information, and reduced cost through fast and proper diagnosis of a boiler system problem.




The method used in HIP


100


for displaying information offers many advantages, some of which have been described. In addition, it provides quick viewing of a boiler node status without the user being overwhelmed with information at the point level. System boiler information is typically viewable on one screen. The method provides for easy navigation at a system level to nodes that require more attention or have problems. Significant diagnostics abilities are provided though monitoring at the “system level” view. By viewing of the data at the system level menu, a system perspective of the performance and problems can be observed without ever taking the time to view the individual point information screens for the sequencer and 3 modular boilers.




Thus, since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.












APPENDIX









PSEODOCODE FOR SEQUENCING RUNTIME

























(Turns on lowest runtime)







(Turns off high runtime)





































































































































Claims
  • 1. A method of controlling a plurality of energy systems to meet an energy need while giving consideration to runtime equalization comprising the steps of:providing digital controllers; configuring said controllers for digital network communication with one controller acting as a sequencer and the remaining controllers acting as individual energy system controllers; determining said energy need based on measurements at said sequencer; maintaining a record of cumulative runtime hours of an associated energy system at said individual energy system controllers; sending messages including at least said cumulative runtime hours from said energy system controllers to said sequencer; ranking said energy systems at said sequencer based on said cumulative runtime hours; and sending control commands from said sequencer to said energy system controllers to add or delete energy systems based on said energy need wherein an energy system to be added has the lowest cumulative runtime hours among available non operating energy systems and an energy system to be deleted has the highest cumulative runtime hours among operating energy systems.
  • 2. The method of claim 1 wherein said energy systems are capable of a variable output and said step of sending periodic control commands further comprises sending a command to vary said output of said energy system.
  • 3. The method of claim 1 wherein said step of sending periodic control commands from said sequencer to said energy system controllers to add or delete energy systems based on said energy need comprises the step of compensating for a first energy system that is selected to be added but is not available for operation by adding a second energy system to meet said energy need.
  • 4. The method of claim 2 wherein said energy systems are boilers having a variable firing rate.
  • 5. The method of claim 2 wherein said energy systems are water heaters having a variable firing rate.
  • 6. The method of claim 2 wherein the highest efficiency of an energy system occurs when said energy system is operating at a reduced capacity and said step of turning on an energy system comprises the step of evaluating the efficiency of an alternative number of operating boilers.
  • 7. A system for controlling a plurality of boilers while giving consideration to runtime equalization, comprising:a first digital controller acting as a sequencer node; a plurality of second digital controllers acting as boiler nodes, with each second controller connected to one of said plurality of boilers; said sequencer node and said boiler nodes configured for digital network communication of control information; means at said sequencer node for determining a heating need and turning on a boiler or turning off a boiler based on said heating need; storage means at each boiler node for maintaining a record of a cumulative runtime of an associated boiler; and means at said sequencer node for receiving said cumulative runtime information from said boiler nodes and ranking said plurality of boilers based on said cumulative runtimes wherein a boiler to be added has the lowest cumulative runtime hours among available non operating boilers and a boiler to be deleted has the highest cumulative runtime hours among operating boilers with said system compensating for a boiler that is not operational by selecting an alternate boiler.
  • 8. The system of claim 7 wherein each boiler of said plurality of boilers is capable of variable output and said system further comprises means for sending periodic control commands to vary an output of said boiler.
  • 9. The system of claim 7 wherein said means for turning a boiler on or turning a boiler off comprises means for evaluating the efficiency of an alternative number of operating boilers.
  • 10. A method of controlling a plurality of energy systems to meet an energy need while giving consideration to runtime equalization, comprising the steps of:providing digital controllers; configuring said controllers for digital network communication with one controller acting as a sequencer and the remaining controllers acting as energy system controllers; determining said energy need based on measurements at said sequencer; maintaining a record of cumulative runtime hours of an associated energy system at said individual energy system controllers; said energy system controllers periodically sending messages including energy system identifiers and said cumulative runtimes hours; ranking said energy systems at said sequencer based on said runtimes hours; and sending control commands from said sequencer to said energy system controllers to add or delete energy systems based on said energy need wherein an energy system to be added has the lowest cumulative runtime hours among available non operating energy systems and an energy system to be deleted has the highest cumulative runtime hours among operating energy systems.
  • 11. The method of claim 10 wherein said energy systems are capable of a variable output and said step of sending periodic control commands further comprises sending a command to vary said output of said energy system and said messages from said energy system controllers include an energy system load value.
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