Universal apparatus and method for configurably controlling a heating or cooling system

• US 8,643,315 B2
• Filed: 10/26/2010
• Issued: 02/04/2014
• Est. Priority Date: 04/22/2008
• Status: Active Grant

• Current Assignee: Copeland Comfort Control LP (Emerson Electric Company)
• Original Assignee: Emerson Electric Company
• Inventors: Butler, William P., Evans, Edward B., Lorenz, Thomas B., Mueller, Carl J., Carey, Steven L., Vogel, G. Scott
• Primary Examiner(s): DUDA, RINA I
• Application Number:
  US12/912,245
• Publication Number:
  US 20110066289A1
• Time in Patent Office: 1,197 Days
• Field of Search: 318/569, 318/600, 318/461, 318/3, 318/9
• US Class Current: 318/3
• CPC Class Codes: F04D 27/004 by varying driving speed
• CPC Class Codes: F24F 11/54 using one central controller connected to several sub-controllers
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: G05D 23/1917 using digital means
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A system for controlling the operation of a heating or cooling system includes a system controller, a memory in which system parameter information relating to the heating or cooling system is stored, and a communication device through which the system controller is configured to transmit and receive signals to/from at least one component controller. The system controller is configured to receive via the communication device a data signal from the at least one component controller that includes information relating to operational parameters for at least one system component installed in the heating and cooling system. The system controller is configured to store in the memory the received operational parameters corresponding to the at least one system component. The stored operational parameters may be retrievable for communication to a replacement component controller in the event that the at least one component controller is replaced.

Claims

1. A system for controlling the operation of a heating and/or cooling system, comprising:

a system controller of a heating and/or cooling system; and

a component controller for controlling a blower motor, the component controller being configured to transmit, to the system controller after the component controller has been installed but before the component controller has been configured for operation in the heating and/or cooling system, information specifying at least a motor type of the blower motor that is installed and is to be controlled by the component controller in the heating and/or cooling system;

the system controller having a local memory in which system parameter information relating to the heating and/or cooling system is stored, said system parameter information including motor related parameters for various types of blower motors, the system controller being configured to send, to the component controller before the component controller has been configured for operation in the heating and/or cooling system, and based on the motor type transmitted by the component controller, at least some of the motor related parameters for the blower motor to thereby provide at least some motor related parameters for use in controlling operation of the blower motor in the heating and/or cooling system.

2. The system of claim 1 wherein the system controller is configured to request the operation of the blower motor through the communication of one or more command signals to the component controller for controlling the blower motor, where each command signal includes parameter information specific to the component controller and the blower motor.

3. The system of claim 1 wherein the system controller requests the operation of the blower motor at a particular airflow in terms of cubic feet per minute (CFM), by communicating command signals to the component controller for controlling the blower motor, where the command signals include the requested CFM and parameter information specific to the component controller and blower motor.

4. The system of claim 1 wherein said system parameter information includes one or more of the following:

a manufacturer identification number associated with the type of blower motor, and the horsepower rating of the installed blower motor.

5. The system of claim 1 wherein upon replacement of the component controller for the blower motor with a replacement component controller, the replacement component controller is configured to receive configuration data from the system controller.

6. The system of claim 1 wherein the component controller includes a memory device on which system parameter information is stored, the system further configured to retrieve the system parameter information from the component controller to configure a replacement system controller if the installed system controller requires replacement.

7. The system of claim 1, wherein the system controller is configured to provide configuration data to a replacement component controller in response to user input signals.

8. The system of claim 7, wherein the system includes a thermostat having an input interface that allows a user to input information including the user input signals.

9. A system for controlling the operation of a heating and/or cooling system, comprising:

a system controller of a heating and/or cooling system; and

a component controller for controlling a blower motor, the component controller being configured to transmit, to the system controller over a communication device after the component controller has been installed but before the component controller has been configured for operation in the heating and/or cooling system, data signals that include information specifying at least a motor type of the blower motor that is installed and that the component controller is to control when configured in the heating or cooling system;

the system controller configured to receive, after configuration of the component controller for operation in the heating and/or cooling system, configuration data including motor related parameters from the component controller for the blower motor and to store the motor related parameters corresponding to the blower motor;

whereby a replacement controller is configured to receive the stored motor related parameters from the system controller after installation of the replacement controller to replace the component controller.

10. The system of claim 9 wherein the system controller selects the at least some of the motor related parameters to send to the component controller based on the motor type of the blower motor transmitted by the component controller.

11. The system of claim 9 wherein the system controller is configured to request the operation of the blower motor through the communication of one or more command signals to the component controller for controlling the blower motor, where each command signal includes parameter information specific to the component controller and blower motor.

12. The system of claim 9 wherein the system controller requests the operation of the blower motor at a particular airflow in terms of cubic feet per minute (CFM), by communicating command signals to the component controller for controlling the blower motor, where the command signals include the requested CFM and parameter information specific to the component controller and blower motor.

13. The system of claim 9 wherein the motor related parameters include one or more of the following:

a manufacturer identification number associated with the type of blower motor, and the horsepower rating of the installed blower motor.

14. The system of claim 9 wherein the component controller includes a memory device on which system parameter information is stored, the system further configured to retrieve the system parameter information from the component controller to configure a replacement system controller if the installed system controller requires replacement.

15. The system of claim 9, wherein the system controller is configured to provide stored configuration data to a replacement component controller in response to user input signals.

16. The system of claim 15, wherein the system includes a thermostat having an input interface that allows a user to input information including the user input signals.

17. A system for controlling the operation of a heating and/or cooling system, comprising:

a system controller of a heating and/or cooling system;

a memory associated with the system controller in which system parameter information relating to the heating and/or cooling system is stored, said system parameter information including a plurality of operational parameters corresponding to a plurality of heating and/or cooling system component types, where a given system component of a given one of the types may be selected and installed in the system from among other components of the given type and for which at least some of the operating parameters are provided; and

a communication device through which the system controller is configured to transmit signals to and/or to receive signals from at least one component controller for controlling at least one system component of the heating and/or cooling system;

wherein the system controller is configured to receive from the at least one component controller over the communication device a data signal that includes information relating to operational parameters for the at least one system component that is installed in the system, said system controller being configured to store in the memory the received operational parameters corresponding to the at least one system component;

the received operational parameters stored by the system controller being retrievable for communication to a replacement component controller in the event that the at least one component controller is replaced.

18. The system of claim 17 wherein the at least one component controller comprises a controller for a blower motor, and the types of heating and/or cooling system components comprise a plurality of types of blower motors, and the operational parameters comprise at least one motor related parameter corresponding to at least one type of blower motor.

19. The system of claim 18 wherein the system controller is configured to request the operation of the blower motor through the communication of one or more command signals to the controller for the blower motor, where each command signal includes parameter information specific to the blower motor controller and blower motor.

20. The system of claim 18 wherein the system controller requests the operation of the blower motor at a particular airflow in terms of cubic feet per minute (CFM), by communicating command signals to the blower motor controller for controlling the blower motor, where the command signals include the requested CFM and parameter information specific to the blower motor controller and blower motor.

21. The system of claim 17 wherein the at least one component controller comprises an air conditioning system controller that controls-a compressor and fan motor, and the types of heating and/or cooling system components comprise a plurality of component sizes, and operational parameters include at least one parameter corresponding to tonnage of the compressor.

22. The system of claim 17 wherein the at least one component controller includes a memory device on which parameter information of at least one other component controller is stored, the system further configured to retrieve the parameter information from the at least one component controller to configure a replacement for the at least one other component controller if the at least one other component controller requires replacement.

23. The system of claim 17 wherein the at least one component controller includes a memory device on which system parameter information is stored, the system further configured to retrieve the system parameter information from the at least one component controller for communication to a replacement system controller.

24. The system of claim 17 wherein the memory associated with the system controller comprises a removable memory device removable from the system controller to retain the system parameter information stored on the removable memory device for use if the system controller requires replacement.

25. The system of claim 17 wherein the communication device comprises a Universal Asynchronous Serial Port that provides a predetermined baud rate serial bit stream signal, a 4-wire BUS connection, or wireless communication means.

26. The system of claim 17 wherein the memory associated with the system controller is local to the system controller, and wherein the system further comprises a memory module connected to the system controller, wherein the system parameter information stored in the local memory of the system controller is also stored in the memory module.

27. The system of claim 26 wherein the system controller is configured to detect the installation of a memory module in which stored system parameters are absent and to copy the system parameter information stored in the local memory of the system controller to the memory module connected to the system controller.

28. The system of claim 26 wherein the system controller is configured to synchronize the local memory with the memory module.

29. The system of claim 26 wherein the memory module is connected to the system controller via a Universal Serial Bus (USB) interface.

30. The system of claim 26 wherein the memory module is removable from the system controller and reconnectable to a blank replacement controller having a local memory, whereby the replacement controller when connected to the memory module synchronizes its local memory to the memory module by copying the system parameter information from the memory module to the local memory of the replacement controller.

31. The system of claim 26 wherein the system is configured with a synchronizing priority for determining which of the local memory and the memory module is dominant, whereby the local memory is dominant unless the absence of any stored system parameter information in the local memory is detected whereupon the memory module is dominant until the system parameter information from the memory module is stored to the local memory which then becomes dominant.

32. The system of claim 31 wherein the synchronizing priority is established by the presence of a default code on a replacement controller that indicates that a local memory of the replacement controller is not dominant, which default code is overwritten and no longer detectable when the system parameter information is stored to the local memory of the replacement controller.

33. The system of claim 26 further comprising an input interface configured to permit system parameter information relating to the heating or cooling system to be input, whereby the system parameter information input via the input interface is stored in the memory module and the local memory of the system controller.

34. The system of claim 17, wherein the system controller and the at least one component controller comprise at least one or more of a controller for a blower motor, a controller for an air conditioning system, and a thermostat.

35. The system of claim 17, wherein the system controller is configured to provide the received operational parameters stored by the system controller to the replacement component controller in response to user input signals.

36. The system of claim 35, wherein the system includes a thermostat having an input interface that allows a user to input information including the user input signals.