Incremental actuator with feedback control diagnostics

1. A controller for controlling operation of an actuator in a heating, ventilation, or air conditioning (HVAC) system, the controller comprising a processing circuit configured to:

receive, via a position sensor communicatively coupled to the actuator, a first voltage value, the first voltage value indicative of a first position of the actuator;

provide a control signal to the actuator to move to a second position;

in response to the actuator moving to the second position, determine that the actuator is located in a different position than the second position based on a second voltage value via the position sensor; and

automatically perform a fault correction process to calculate an updated stroke range of the actuator, wherein the fault correction process comprises:

determining an initial stroke range indicative of a time period for the actuator to move from a first endpoint to a second endpoint;

instructing the actuator to move to the first endpoint for a first period greater than the initial stroke range;

receiving a first test voltage signal at the first endpoint;

instructing the actuator to move to the second endpoint for a second period greater than the initial stroke range;

receiving a second test voltage signal at the second endpoint; and

calculating the updated stroke range based on the initial stroke range, the first test voltage signal, and the second test voltage signal.

2. The controller of claim 1 , wherein:

the position sensor is a potentiometer; and

the controller is configured to receive a plurality of voltage signals from the potentiometer, each of the plurality of voltage signals corresponding to a location between the first endpoint and the second endpoint, the plurality of voltage signals comprising the first voltage value and the second voltage value.

3. The controller of claim 1 , wherein calculating the updated stroke range comprises calculating an effective stroke time, wherein the effective stroke time is a calculated period for the actuator to move from the first endpoint to the second endpoint.

4. The controller of claim 3 , wherein calculating the updated stroke range comprises:

performing a calculation, the calculation comprising:

S

⁢

R

U

[

V

]

=

(

V

H

-

H

L

)

*

[

S

⁢

T

E

S

⁢

T

F

]

wherein:

SR U is the updated stroke range, V H is the first test voltage signal, V H is the second test voltage signal, ST E is the effective stroke time, and ST F is a full stroke time; and

the full stroke time is a predetermined period for the actuator to complete the initial stroke range.

5. The controller of claim 1 , wherein the position sensor is a potentiometer.

6. A controller for controlling operation of an actuator in a heating, ventilation, or air conditioning (HVAC) system, the controller comprising a processing circuit configured to:

receive, via a position sensor communicatively coupled to the actuator, a first voltage value, the first voltage value indicative of a first position of the actuator;

provide a control signal to the actuator to move to a second position;

in response to the actuator moving to the second position, determine that the actuator is located in a different position than the second position based on a second voltage value via the position sensor; and

automatically perform a fault correction process to calculate an updated stroke range of the actuator, wherein automatically performing the fault correction process comprises:

determining that the actuator is located substantially close to the second position;

determining that a fault has occurred due to actuator drift; and

performing the fault correction process to correct for the actuator drift.

7. The controller of claim 6 , wherein performing the fault correction process to correct for the actuator drift comprises performing a periodic overdrive sequence to resynchronize the actuator.

8. A method for controlling operation of an actuator in a heating, ventilation, or air conditioning (HVAC) system, the method comprising:

receiving, via a position sensor communicatively coupled to the actuator, a first voltage value, the first voltage value indicative of a first position of the actuator;

providing a control signal to the actuator to move to a second position;

in response to the actuator moving to the second position, determining that the actuator is located in a different position than the second position based on a second voltage value via the position sensor; and

automatically performing a fault correction process to calculate an updated stroke range of the actuator, wherein the fault correction process comprises:

determining an initial stroke range indicative of a time period for the actuator to move from a first endpoint to a second endpoint;

instructing the actuator to move to the first endpoint for a first period greater than the initial stroke range;

receiving a first test voltage signal at the first endpoint;

instructing the actuator to move to the second endpoint for a second period greater than the initial stroke range;

receiving a second test voltage signal at the second endpoint; and

calculating the updated stroke range based on the initial stroke range, the first test voltage signal, and the second test voltage signal.

9. The method of claim 8 , wherein:

the position sensor is a potentiometer; and

the method further comprises receiving a plurality of voltage signals from the potentiometer, each of the plurality of voltage signals corresponding to a location between the first endpoint and the second endpoint, the plurality of voltage signals comprising the first voltage value and the second voltage value.

10. The method of claim 8 , wherein calculating the updated stroke range comprises calculating an effective stroke time, wherein the effective stroke time is a calculated period for the actuator to move from the first endpoint to the second endpoint.

11. The method of claim 10 , wherein calculating the updated stroke range comprises:

performing a calculation, the calculation comprising:

S

⁢

L

U

[

V

]

=

(

V

H

-

V

L

)

*

[

S

⁢

T

E

S

⁢

T

F

]

wherein:

ST U is the updated stroke range, V H is the first test voltage signal, V H is the second test voltage signal, ST E is the effective stroke time, and ST F is a full stroke time, and

the full stroke time is a predetermined period for the actuator to complete the initial stroke range.

12. The method of claim 8 , wherein the position sensor is a potentiometer.

13. A method for controlling operation of an actuator in a heating, ventilation, or air conditioning (HVAC) system, the method comprising:

receiving, via a position sensor communicatively coupled to the actuator, a first voltage value, the first voltage value indicative of a first position of the actuator;

providing a control signal to the actuator to move to a second position;

in response to the actuator moving to the second position, determining that the actuator is located in a different position than the second position based on a second voltage value via the position sensor; and

automatically performing a fault correction process to calculate an updated stroke range of the actuator, wherein automatically performing the fault correction process comprises:

determining that the actuator is located substantially close to the second position;

determining that a fault has occurred due to actuator drift; and

performing the fault correction process to correct for the actuator drift.

14. The method of claim 13 , wherein performing the fault correction process to correct for the actuator drift comprises performing a periodic overdrive sequence to resynchronize the actuator.

15. A control system for controlling operation of an actuator in a heating, ventilation, or air conditioning (HVAC) system, the control system comprising:

the actuator communicatively coupled to a position sensor; and

a controller comprising a processing circuit configured to:

receive, via the position sensor, a first voltage value, the first voltage value indicative of a first position of the actuator;

provide a control signal to the actuator to move to a second position;

in response to the actuator moving to the second position, determine that the actuator is located in a different position than the second position based on a second voltage value via the position sensor; and

automatically perform a fault correction process to calculate an updated stroke range of the actuator, wherein the fault correction process comprises:

determining an initial stroke range indicative of a time period for the actuator to move from a first endpoint to a second endpoint;

instructing the actuator to move to the first endpoint for a first period greater than the initial stroke range;

receiving a first test voltage signal at the first endpoint;

instructing the actuator to move to the second endpoint for a second period greater than the initial stroke range;

receiving a second test voltage signal at the second endpoint; and

calculating the updated stroke range based on the initial stroke range, the first test voltage signal, and the second test voltage signal.

16. The control system of claim 15 , wherein:

the position sensor is a potentiometer; and

the controller is configured to receive a plurality of voltage signals from the potentiometer, each of the plurality of voltage signals corresponding to a location between the first endpoint and the second endpoint, the plurality of voltage signals comprising the first voltage value and the second voltage value.

17. The control system of claim 15 , wherein calculating the updated stroke range comprises calculating an effective stroke time, wherein the effective stroke time is a calculated period for the actuator to move from the first endpoint to the second endpoint.

18. The control system of claim 17 , wherein calculating the updated stroke range comprises:

performing a calculation, the calculation comprising:

S

⁢

L

U

[

V

]

=

(

V

H

-

V

L

)

*

[

S

⁢

T

E

S

⁢

T

F

]

wherein:

SR U is the updated stroke range, V H is the first test voltage signal, V H is the second test voltage signal, ST E is the effective stroke time, and ST F is a full stroke time,

the full stroke time is a predetermined period for the actuator to complete the initial stroke range.

19. The control system of claim 15 , wherein the position sensor is a potentiometer.

20. A control system for controlling operation of an actuator in a heating, ventilation, or air conditioning (HVAC) system, the control system comprising:

the actuator communicatively coupled to a position sensor; and

a controller comprising a processing circuit configured to:

receive, via the position sensor, a first voltage value, the first voltage value indicative of a first position of the actuator;

provide a control signal to the actuator to move to a second position;

in response to the actuator moving to the second position, determine that the actuator is located in a different position than the second position based on a second voltage value via the position sensor; and

automatically perform a fault correction process to calculate an updated stroke range of the actuator, wherein automatically performing the fault correction process comprises:

determining that the actuator is located substantially close to the second position;

determining that a fault has occurred due to actuator drift; and

performing the fault correction process to correct for the actuator drift.