System and method for loading software into a control panel for a chiller system

• US 20050039471A1
• Filed: 08/12/2004
• Published: 02/24/2005
• Est. Priority Date: 08/15/2003
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: York International Corporation (Johnson Controls International plc)
• Inventors: Smith, Bart Andrew, Boyer, Jeffrey Daniel
• Granted Patent: US 7,434,089 B2
• Time in Patent Office: Days
• US Class Current: 62/157
• CPC Class Codes: F25B 49/00 Arrangement or mounting of control or safety devices
• CPC Class Codes: G05B 19/0426 Programming the control sequence
• CPC Class Codes: G05B 2219/23307 Initial program loader, ipl, bootstrap loader
• CPC Class Codes: G05B 2219/23339 Update diskette, cassette initiates bootstrap program to load eeprom, flash
• CPC Class Codes: G05B 2219/23342 Pluggable rom, smart card
• CPC Class Codes: G05B 2219/23417 Read program from pluggable memory card
• CPC Class Codes: G05B 2219/2654 Fridge, refrigerator
• CPC Class Codes: G06F 8/65 Updates security arrangements therefor G06F21/57

Abstract

A system and process for loading control software into the control panel of a liquid chiller system is provided. A PCMCIA card socket is installed on a circuit board of a liquid chiller control system and is in direct connection with microprocessor data and address buses. A linear flash PCMCIA card having new control software for the control panel is inserted into the PCMCIA card socket when the control panel is de-energized. The control software from the PCMCIA card is loaded into a flash memory of the control system by software executed directly from the PCMCIA card. The software in the PCMCIA card erases the flash memory of the control system, copies the control software from the PCMCIA card to the flash memory and then confirms that the copy of the control software was successful. After the control software has been copied, the control panel is de-energized, the PCMCIA card is removed and the chiller system is restarted and executes the new control software stored in the flash memory.

Claims

1. A method of loading software into a control panel of a chiller system, the method comprising the steps of:

inserting a linear flash PCMCIA card into a corresponding socket on a control panel of a chiller system;

initializing the chiller system with a boot program stored on the linear flash PCMCIA card;

copying a software program stored on the linear flash PCMCIA card to a memory device on the control panel with a copy program stored on the linear flash PCMCIA card; and

removing the linear flash PCMCIA card from the corresponding socket on the control panel of the chiller system.

2. The method of claim 1 wherein the step of copying a software program includes the step of verifying that the software program has been copied successfully to the memory device on the control panel.

3. The method of claim 2 wherein the step of verifying that the software program has been copied successfully includes the step of comparing byte by byte program information stored in the memory device with corresponding program information stored in the PCMCIA card.

4. The method of claim 2 wherein the step of verifying that the software program has been copied successfully includes the steps of:

calculating a checksum value for the copied software program stored in the memory device; and

comparing the calculated checksum value with a corresponding checksum value for the software program stored in the PCMCIA card.

5. The method of claim 1 wherein the control panel comprises an application memory and a boot memory and the memory device on the control panel being one of the application memory and the boot memory.

6. The method of claim 5 wherein at least one of the application memory and the boot memory do not contain any software programs.

7. The method of claim 1 wherein the step of copying a software program includes the step of erasing the memory device before the software program stored on the linear flash PCMCIA card is transferred to the memory device.

8. The method of claim 1 wherein the step of copying a software program includes the steps of:

displaying software installation information, the software installation information including a plurality of software programs stored in the linear flash PCMCIA card; and

selecting a software program from the plurality of software programs to be installed in the memory device.

9. The method of claim 1 wherein the step of inserting a linear flash PCMCIA card includes the steps of:

de-energizing the control panel;

inserting the linear flash PCMCIA card into the corresponding socket of the control panel after the control panel has been de-energized; and

energizing the control panel after the linear flash PCMCIA card is inserted in the corresponding socket of the control panel.

10. The method of claim 1 wherein the step of removing the linear flash PCMCIA card includes the steps of:

de-energizing the control panel;

removing the linear flash PCMCIA card from the corresponding socket of the control panel after the control panel has been de-energized; and

energizing the control panel after the linear flash PCMCIA card is removed from the corresponding socket of the control panel.

11. A control panel for a chiller system, the control panel comprising:

a microprocessor;

a PCMCIA connector configured to receive a linear flash PCMCIA card, the PCMCIA connector being connected to the microprocessor by an address bus and a data bus to provide direct communication between the PCMCIA connector and the microprocessor;

an application memory connected to the address bus and the data bus, the application memory being configured to store control software;

a boot memory connected to the address bus and the data bus, the boot memory being configured to store initialization software; and

steering logic, the steering logic being configured to initiate execution of initialization software stored in one of the boot memory and a linear flash PCMCIA card inserted in the PCMCIA connector.

12. The control panel of claim 11 wherein the microprocessor provides an output control signal to the steering logic to initiate a boot procedure for the control panel.

13. The control panel of claim 12 wherein the output control signal is an active low signal.

14. The control panel of claim 13 wherein the microprocessor provides the output control signal to the PCMCIA connector and the PCMCIA connector includes an active low input to receive the output control signal.

15. The control panel of claim 11 wherein the steering logic provides a boot signal to the boot memory.

16. The control panel of claim 15 wherein the boot memory comprises an active low input to receive the boot signal from the steering logic.

17. The control panel of claim 11 wherein the PCMCIA connector provides a card detect signal to the steering logic indicating a PCMCIA card is inserted in the PCMCIA connector.

18. The control panel of claim 17 wherein the card detect signal is an active low signal.

19. The control panel of claim 11 further comprising a display to present information to a user.

20. The control panel of claim 11 further comprising a data entry device and a device interface circuit connected to the data bus.

21. The control panel of claim 11 wherein:

the microprocessor provides an output control signal to the steering logic to initiate a boot procedure for the control panel, the output control signal is an active low signal;

the PCMCIA connector provides a card detect signal to the steering logic indicating a PCMCIA card is inserted in the PCMCIA connector, the card detect signal is an active low signal; and

the steering logic further comprises;

an inverter, the inverter being configured to invert the card detect signal from the PCMCIA connector; and

an OR gate, the OR gate being configured to receive the output control signal and the inverted card detect signal as inputs and provide as an output a boot signal to the boot memory.

22. A method of loading software onto a plurality of chiller system control panels, the method comprising the steps of:

inserting a linear flash PCMCIA card into a corresponding socket of a chiller system control panel;

initializing a chiller system with a boot program stored on the linear flash PCMCIA card;

copying a software program stored on the linear flash PCMCIA card to a memory device on the control panel with a copy program stored on the linear flash PCMCIA card;

removing the linear flash PCMCIA card from the corresponding socket of the chiller system control panel; and

repeating the steps of inserting a linear flash PCMCIA card, initializing a chiller system, copying a software program, and removing the linear flash PCMCIA card for another chiller system control panel.

23. The method of claim 22 wherein the step of copying a software program includes the step of verifying that the software program has been copied successfully to the memory device on the control panel.

24. The method of claim 22 wherein the step of copying a software program includes the step of erasing the memory device before the software program stored on the linear flash PCMCIA card is transferred to the memory device.

25. The method of claim 22 wherein the step of inserting a linear flash PCMCIA card includes the steps of:

de-energizing the control panel;

inserting the linear flash PCMCIA card into the corresponding socket of the control panel after the control panel has been de-energized; and

energizing the control panel after the linear flash PCMCIA card is inserted in the corresponding socket of the control panel.

26. The method of claim 22 wherein the step of removing the linear flash PCMCIA card includes the steps of:

de-energizing the control panel;

removing the linear flash PCMCIA card from the corresponding socket of the control panel after the control panel has been de-energized; and

energizing the control panel after the linear flash PCMCIA card is removed from the corresponding socket of the control panel.