Fan Array Diagnostic and Monitoring System and Method

Abstract

An air-handling system includes one or more fan arrays that each include a plurality of fan assemblies. Each fan assembly includes a motor operatively connected to an impeller, and a motor controller operatively connected to the motor. A control module is operatively connected to the motor controllers and is configured to determine a status of the operating parameters of each motor controller based on actual parameter value information received from the motor controller and expected parameter value information.

1 . A method of diagnosing and monitoring fan assemblies forming fan arrays, the method comprising:
 generating, by a control module, a first parameter status inquiry and sending the first parameter status inquiry to a first motor controller of a first fan assembly of a first fan array;   receiving, at the control module, a first actual parameter value of a first operating parameter from the first motor controller;   comparing, by the control module, the first actual parameter value and a first expected parameter value of the first operating parameter;   determining, by the control module, a parameter status of the first motor controller based on the comparison of the first actual parameter value and the first expected parameter value; and   writing, by the control module, the first expected parameter value to the first motor controller as the first actual parameter value of the first operating parameter based on the parameter status being an invalid parameter status.   
     
     
         2 . The method of  claim 1 , further comprising:
 generating, by the control module, an error notification based on the parameter status of the first fan assembly being an invalid status; and   sending, by the control module, the error notification to a user interface.   
     
     
         3 . The method of  claim 1 , wherein determining, by the control module, the parameter status of the first motor controller based on the comparison of the first actual parameter value and the first expected parameter value includes:
 determining, by the control module, that the parameter status of the first motor controller is a valid status based on the first actual parameter value matching the first expected parameter value.   
     
     
         4 . The method of  claim 1 , wherein determining, by the control module, the parameter status of the first motor controller based on the comparison of the first actual parameter value and the first expected parameter value includes:
 determining, by the control module, that the parameter status of the first motor controller is an invalid status based on the first actual parameter value being different than the first expected parameter value.   
     
     
         5 . The method of  claim 1 , wherein writing, by the control module, the first expected parameter value to the first motor controller as the first actual parameter value of the first operating parameter includes:
 writing the first expected parameter value to the first motor controller based on a reconfigure command received by the control module.   
     
     
         6 . The method of  claim 1 , wherein writing, by the control module, the first expected parameter value to the first motor controller as the first actual parameter value of the first operating parameter includes:
 initiating, by the control module, a repair sequence during which the first expected parameter value is written to the first motor controller as the first actual parameter value of the first operating parameter.   
     
     
         7 . The method of  claim 1 , further comprising:
 generating, by a control module, a second parameter status inquiry and sending the second parameter status inquiry to a second motor controller of a second fan assembly of the first fan array;   receiving, at the control module, a second actual parameter value of a second operating parameter from the second motor controller;   comparing, by the control module, the second actual parameter value and a second expected parameter value of the second operating parameter; and   determining, by the control module, a parameter status of the second motor controller based on the comparison of the second actual parameter value and the second expected parameter value.   
     
     
         8 . The method of  claim 7 , further comprising:
 implementing a time delay between determining the parameter status of the first motor controller and generating the second parameter status inquiry.   
     
     
         9 . The method of  claim 7 , wherein the first expected parameter value is the second expected parameter value such that comparing, by the control module, the second actual parameter value and the second expected parameter value includes comparing the second actual operating parameter value and the first expected parameter value. 
     
     
         10 - 17 . (canceled) 
     
     
         18 . A diagnostic and monitoring method for an air-handling system, the method comprising:
 determining, by a control module and for a first fan array including a plurality of first fan assemblies, a plurality of parameter statuses of a first motor controller of each first fan assembly of the plurality of first fan assemblies based on a comparison of a first actual parameter value received from each first motor controller and a first expected parameter value recalled from a memory of the control module; and   configuring, by the control module, a target first motor controller of the plurality of first motor controllers such that the first expected parameter value of the target first motor controller replaces the first actual parameter value for the target first motor controller based on the control module determining an invalid parameter status for the target motor controller;   wherein the control module is configured to determine a parameter status of each target first motor controller prior to determining a parameter status of each next first motor controller.   
     
     
         19 . The method of  claim 18 , further comprising:
 determining, by the control module and for a second fan array including a plurality of second fan assemblies, a plurality of parameter statuses of a plurality of second motor controllers of each second fan assembly of the plurality of second fan assemblies based on a comparison of a second actual parameter value received from the second motor controller and a second expected parameter value recalled from the memory of the control module.   
     
     
         20 . The method of  claim 19 , further comprising:
 repeating, by the control module, determining the plurality of parameter statuses of the plurality of first motor controllers after determining the plurality of parameter statuses of the plurality of second motor controllers.