Product development and performance tests of three programmable microprocessor controllers for use with solar heating and cooling systems are presented. The products were developed to be marketable for public use

Hankins, J. D.

English

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G 3/44
(NASA-TM-78246)	 DEVELOPMENT AN0 TFSTING Of
THE RHO SIGMA INCCFPOFATEC MTCFOPFCCfSSCR
CONTFOL SUHSYSTF1 final Fepott (NASA)	 23 p
HC 402/MF A01	 CSCL 10A
V
NSO-14496
Uncla
46454
DOE/NASA TECHN I CAL ME,MORANEUM
DOE/NASA TM-78246
DEVELOPMENT AND TESTING OF THE RHO SIGMA INCOP o%r%TED
MICROPROCESSOR CuNTROL SUBSYSTEM--FINAL REPORT
By James D. Hankins
Solar Energy Applications Projects
George C. Marshall Space Flight Center
]Marshall Space Flight Center, Alabama 35812
October 1979
i
U.S. Department of Energy
Safer Energy
TABLE OF CONTENTS
Page
SUMMARY.......................................
	
I
INTRODUCTION	 .....	 ....	 .......................
	
3
PURPOSE OF THIS PRODUCT DEVELOPMENT CONTRACT .....
	
3
DESCRIPTION OF PROJECT DEVELOPMENT REQUIREMENTS
AND CRITERIA
	 ......	 4
DESCRIPTION OF THE RS 600 PROGRAMMABLE CONTROL
SYSTEM	 4
CONCLUSIONS AND RECOMMENDATIONS .................
	
17
APPLICABLE DOCUMENTS .........................
	 18
,i.
QRECEDING PAGE BLANK NOT F
LI ST OF ILLUSTRATIONS
Figure Title Page
1. Existing solar heating and control subsystem was
implemented in a solar energy data acquisition
system
	 .................................. 2
2. Controller Front with Cover Closed	 .............. 5
3. Programmable C::..trol System	 ........... ....... 7
4. Front Panel of the Controller.	 .................. 8
5. 5 Digit LED Display ........................... 9
6. 16 Key Keyboard	 ....................	 ........ 10
7. Manual Override Switches .
	 .........
	
........	 . 11
8. Controller Basic Layout 	 ....................... 13
9. Plug-In Printed Circuit (PC) Board Assembly • • • • • • • •• 14
10. Internal Controller Box .. 	 ...............	 ... 15
TECHNICAL MEMORANDUM
DEVELOPMENT AND TESTING OF THE RHO SIGMA INCORPORATED
MICROPROCESSOR CONTROL SUBSYSTEM--
FINAL REPORT
SUMMARY
The intended use for this report is to provide product development infor-
mation as an aid to the solar heating and cooling systems manufacturing industry
in their effort to determine the products adaptability for use in a specifically con-
figured total solar heating and/or cooling system for residential and commercial
applications.
This report will also serve as an aid to those who desire to remain abreast
of the state-of-the-art of solar energy heating and cooling projects.
The Rho Sigma Controller as developed under this contract had its begin-
ning from a multi-loop system which was implemented as part of a microcomputer
based data acquisition system (rig, i) as a demou41;, ation of the system's capability
The microprocessor system, because of the data acquisition functions which were
included, was larger than needed for the control Va.sl: and would not sell commer-
cially due to the higher cost. However, it easily controlled several loops and
demonstrated what could be done with a programmable controller.
In October 1976, Rho Sigma ei;,tered into a contract with the National
Aeronautics and Space Administration (NASA)/  Oeorge C. Marshall Space Flight
Center (MSFC) to upgrade the controller to satisfy certain additional requirements
to assure that the product could be classified as a marketable product and suitable
for public use.
The deliverable end item under this contract was three identical micro-
processor control subsystems which could be used in heating, heating and cooling,
and/or hot water systems for single family, inultl-family or commercial applica-
Lions. The controller incorporates a low cost, highly reliable, all-solid-state
microprocessor which can be easily reprogrammed.
	_	 e s
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Figure 1. Existing solar heating and control subsystem was implemented
in a solar energy data acquisition system.
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At contract completion, tuned subsysten-is passed qualification and accept-
ance test, and were delivered to MSFC. These subsystems are classified market-
able for public use.
INTRODUCTION
The problems of energy availability and increasing costs have led to a
major national effort to develop alternate energy sources. One such source is
the energy in solar radiation, which can be used for heating and cooling buildings,
doitestic hot water, and other applications. The National Energy . Polio,
established in the Solar Floating and Cooling Demonstration Act of 197 1  (PL93-409)1
of which the effort described in this final report is part of, provided for the demon-
stration within a 3-year period of the practical use of solar heating technology,
and demonstration within a 5-year period of the practical use of combined heating
and cooling technology. Responsibility for implementing the Demonstration Act
was given to the Energy .Research and Development Administration (now the
Department of Energy) . NASA/MSPO manages a large part of this work.
PURPOSE OF THIS PRODUCT DEVELOPMENT CONTRACT
The purpose of this contract was to provide funding to Elio Sig,11 t, Inc. to
do additional design, development, fabrication, and test work on their t-xisting
subsystem so that each subsystem can be classified as a reliable marketableprod-
uct for publid use.
This second generation system was designed for use with commercial,
n tlti-family dwelling, and complex residential beating, ventilating, and air conditioning
(H17AC) systems. Rs versatility allows Lt to be programmed to control any type
system -,vlieve multiple sensor inputs and control, outputs are heeded.
Contract performance period was from October 13, 1976, through July 29,
1979.
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DESCRIPTION OF PROJECT DEVELOPMENT
REQUIREMENTS AND CRITERIA
During the development of the microprocessor controller, the contractor
was required to:
a) Meet the applicable r , As of the interim performance criteria for solar
heating and cooling systems:
b) Meet the subsystem performance specifications.
c) Provide test data/analysis to verify that hardware meets the subsystem
performance specification.
d) Provide drawings and specifications in sufficient detail to define the
configuration and to ensure manufacturing repeatability.
e) Provide installation, operation and maintenance manuals.
f) Provide subsystems and/or component hardware certification by an
independent test laboratory ( such as Underwriters Laboratory and American Gas
Association) to meet nationally recognized standards and codes ( such as American
Society of Heating, Refrigeration and Air Conditioning Engineers; American Soci-
ety for Mechanical Engineers; American Standards Institute and American ]Refriger-
ation Institute) .
DESCRI PTION OF THE RS 600 PROGRAMMABLE
CONTROL SYSTEM
The RS 600 Programmable Control System (PCS) ( Fig. 2) is a highly
versatile, programmable controller. It accepts inputs from a wide variety of
sensors and converts them to engineering units. Control equations, customer
designated, are then solved and the appropriate outputs occur. Typical of the
equations are those used in a solar heating system which include: differential
temperature measurement to turn the appropriate pumps on, turning back-up sys-
tems on when solar is not enough, and off-peak control for back-up systems.
Fi9Ure 2. COIltrollut .
 Fr(mt %^itlj C'Mur ('lonud.
'RIGINAL PAGE is
OF POOR QUAL *1~f
The Control System utilizes a Fairchild F8 microprocessor to perform
all timing, control and calculation functions. The microprocessor follows a pro-
gram which is stored on plug-in, UV eraseable Programmable Read Only Mem-
ories (PROM' s) . These, PROM' s are changed to customize the system' s per-
formance for individual control' requireri-ients.
Figure 3 shows the general block diagram of the PCS. Figure 4 shows
the front panel of the PCS with the keyboard/ display and the output monitor and
control switches.
The RS 600 has a "front end conditioning" module which is designed to
allow the use of thermistors as temperature sensors. There are 16 such analog
Inputs available along with 16 discrete inputs.
An optional 5-digit LED display and the 16-key keyboard are mounted
Inside the RS 600 enclosure as shown in Figures 5 and 6. This display will
automatically sequence through all input channels or can be set to monitor one
channel via the keyboard. The display is in engineering units for the analog
channels. The discrete input channels will be represented by "HI" or "LO" for
"ON" and "OFF".
The display also will show the time by day of year, hour, and minute.
Time can be changed via the keyboard for initialization and updating in the event
of startup and power outage.
The keyboard, in addition to allowing the user to monitor a particular
input or output channel, can be used to change up to 52 constants used in the pro-
grammed equations. The program constants can be changed via the keyboard to
modify any of the equations. In this manner system changes can be cried without
any hardware modifications.
Sixteen optional LED' s and three-position toggle switches are on the same
panel as the display/ keyboard ( Fig. 4) The LED' s will indicate an output in the
"ON" stage; the toggle switches will allow the user to manually turn each output
to either "ON" or "OFF", or to put the output in the "AUTO" state which is then
under computer control ( Fig. 7) .
There are 16 output control signals whic4 can be used either to drive
contact relays or solid state relays for operating amps, blowers, dampers,
valves, etc.
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The controllor 1.4 pro •ramilit'd to F'olve 11 SO of logic a.1/arIL11111otte aqua-
tions. The Oqllntions 11ro volitftillod in PROM I 8. Tho associated constants for
cach equation tire Lompovartly hold In the liandoill Aemss Momory (11AM) will.ch
will allow Clio usor to alter and Osporimotit with title comotatits via, the koyboard.
Tile following description of the control systoill applios in gollortil to all
PS' (300 , 'g .
 
however, tiro oxact; %)0vifivations for ally lillit 11111y vallyr depoildIlig,
upon the miloulit Of ('11stollitzing, or opttoils. Pipiro 8 prosonts the basic Inyout,
of the 111 600 Controllor,
The volit-iollar 11a.8 8 single 011dod analog InImt chmmols, which calibo
Oxpandod to 16. The Inputs arc usod for thorliltstor t
 lay rallonlotur, fln'tiloters
and Switchod hiputs. Convorsion rato Is 8 dial linols/,21 see or 0.25 soo/chantiol,
Optional thornitstor etvelitt vards provide reforotico resistors for 10000 ohm
thormistors. Standard thormistor autpul; Is 11 ►10firized om, a vailgo of -400 to
+3000 V. Emel1 thormistor otroult card vontatno 8 thornitstor rareronoo rost'gtors
and a 1.7 roforoneo supply, Powor .9tipply drift is 0.	 0 llin.-411111111. T-Alloar[mv-
atoll error Is :L. x.00 F. Tho analog, hiput Oall (1) aveolilmodato till 111pid from till
allalog flowmator whom 0-2 V is	 Of the flowp
 (2) directly accom-
modate it soltir roll. type pyratiomotor hiptit and with optional amplIflor, (8)) handle
a thermopile type pyratiomotor, slid (4) be WAltzod to handlo ft switch closure
Input. To dobounco the switch, its laptit, wttl be snimod twivo sopara,tcd by Q00
illsoco
Tho Controller (VI( s. 9 and 10) also 11118 8 transistor tra,11siotor logic
eompatible Inputs expaildod to 16. Lolvic 0 is 0+0 V al; 1, 6 mA or a contact; Oo-
Sim of less thall, 800 0111,1,18. Logic I Is +12.4 to + '*) V or an opou oirmilt. Dubounco
Is pro\wtited by requiring 21 eonsocutivo 111puts ► 0. 81 see apfirt, to act; v1poll ilaw
conditions. A pulso type flowmotav can also bo iopiited to Chose hiput:s, provtdod
its -rate is loss thall 2 ,10 p11lsus/lll[1luto4
Thora tire 16 rolay, drtvOv type outputs avallablo tiltwnlally to 0110 ) Cq_
,Clioso outputs oall. drive Q(thor solid state or contact rolftys to PrON)WO 16 differ-
out mitrol functions. Tllo typos of rolays usod W1,11 dopolid, 11poll 010 cust"01110r , 8
systom raquiro.mallts. Optleally emiplod, solid stal;o switehos area avall4blo fts
control outputs. Thay van, be usod to run pulllPs t 'falls, Dad volit-vot vftivas. Oat-
puts mul also be proporti.onally mitrollod. Tho ovtgut is 1414) ,0 V at, 10 amps.
Cont-ict relays are avallable tis controlled outputs.. Tho typo tisod (J)P/1)T, SP/
ST, etc. ) wilt dapead oil Clio vusComcr , s noods.
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ORIGINAL PAGE L9
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MThe multifunction display of the Controller uses large, 0.6 in. high LED',s
for good visibility at 25 ft. For each input channel, the display shows the two
digit channel number, proceded by the channel designator. The sequential display
is the value of the channel in engineering units. The display can also be used for
date entering and to show time and date functions. The display shows flashing
time display after a power loss.
The internal calendar clock of the Controller operates on a 365-day year.
The user sets the clock with a switch at power turn-on or by using the keyboard.
The PCS enclosure is 20 x 10 x 30 inches. Four mounting holes are on rear
plane for wall mounting.
Environment
Operating temperature 	 00 to + 50° C
Storage temperature	 -20° to + 70° C
Humidity (no condensation)	 0 to 95 percent
Shock	 normal handling
Vibration	 normal handling
Power
115 Vac :h 10 percent, 60 f 3 Hz, 50 W nominal.
s
16
`r	CONCLUSIONS AND RECOMMENDATIONS
No major problems were encountered during this contract, and the objec-
tive of the contract was successfully accomplished; the delivered Controller
passed all acceptance testing and criteria, and are ready for the market.
The developed microprocessor Controller is not an off-the-shelf item
and must be customized to each user's requirement. ij
The obvious application for the Controller is very complex residential,
commercial, and industrial solar systems. A not so obvious, but cost effective
use Is during the prototype and early operational phase of solar systems, which
after debugging, checkout and operational verification, would perform efficiently
with less sophisticated Controllers. Another very cost effective application,
which is extremely desired with solar, is energy management.
Rho Sigma, hicorporated, North Hollywood, California, should be con-
tacted for additional information concerning the RS-600 Programmable Control
System.
17
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APPLICABLE DOCUMENTS
1. Preliminary Design Package for RS 600 Microprocessor Control Subsys-
tem, DOE/ NASA CR 150628, Contract NAS8-32256, Rho Sigma, Incor-
porated, North Hollywood, California, January 1976.
2. System Design and Installation for RS 600 Programmable Control System
for Solar Heating and Cooling, DOE/ NASA CR 150535, Contract NAS8-
32256, Rho Sigma Incorporated, North Hollywood, California, January
1978.
3,	 Quarterly Reports for RS 600 Programmable Controller Solar Heating
and Cooling, DOE/ NASA CR 150744, Contract NAS8-32256, Rho Sigma
Incorporated, North Hollywood, California, July 1978.
4.	 Proceedings of the First Workshop on The Control of Solar Energy Sys-
tems for Heating and Cooling, 1978, pages 193-195, "Government Role
in Development of Microprocessor Control Systems for Solar Heating and
Cooling," by James D. Hankins, Marshall Space Flight Center, Huntsville,
Alabama.
a
Documents 1, 2, and 3 can be obtained from the Department of Energy, Technical
Information Center (TIC) , Oak Ridge, TN. Document 4 was published by the
Publishing Office of the American Section of the International Solar Energy
Society, Inc. , MdDowell Hall, University of Delaware, Newark, Delaware 19711,
APPROVAL
DEVELOPMENT AND TESTING OF THE RHO SIGMA INCORPORATED
MICROPROCESSOR CONTROL SUBSYSTEM--
FINAL REPORT
By Jaines D. Hankins
The information in this report has been reviewed for technical content.
Review of any information concerning Department of Defense or nuclear energy
activities or programs has been made by the MSDC Security Classification Officer.
This report, in its entirety, has been determined to be unclassified.
WILLIAM A. BIZ KSBANK, JR.
Manager, Solar Energy Applications projects
1
19
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Development and testing of the Rho Sigma Incorporated microprocessor control subsystem

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