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IIT - Universidad Pontificia Comillas

1. 17 Table 3 4 Discrete DIOS india Pa Dua SN dua UD O 30 Table 3 5 LabVIEW specifications 33 Table 3 6 Controls lab specifications esee 33 Table 3 7 Design speciticat DIIS ba 34 Table 3 8 Specifications and deliverables for GUI 40 Table 4 1 Testing methods and results for mobile cart 51 Table 4 2 HVAC Ai 53 Table 4 3 Differential pressures and corresponding flow rates 55 Table 4 4 LabVIEW design specifications and 56 Table 4 5 Matlab specifications and testing esses 57 Report Table 4 7 Efficiency of the air temperature control 62 Table 4 8 Controller and sensor testing miii nn incen 63 Table 4 9 Testing procedure and results for 65 PS Upon um rU 68 Table 1 1 Siemens display parts list 69 Table 1 2 Parts list for HVAC cin 70 o 72 Table 1 1 Description of inputs and outputs 00 73 Report P
2. CONTROLLER PID labview Temperature Sensor Inside box i USB 01 LabVIEW y y RELAY POWER THE 4 4 DAQ 6009 USB 8009 COIL analog Digital output To relays v ACTIVATE FAN POSITION DAMPERS Figure 3 11 Flowchart of Overall Process Control design Apart from the possibility to see and manipulate the response of a PID controller the TOCOM lab aims to allow students to research about the HVAC system design their own controllers and test them in the real system In order to accomplish this objective the model will be implemented in Simulink Matlab starting from the thermodynamics equations for the open loop no recirculating shown below After applying the fist law of thermodynamics 3 Equation 3 1 shows the variation of temperature inside the enclose environment Part I Report P gina 25 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL dU dE gt h s hin ni hour Eq 3 1 Knowing that U 2 mC T W 0 Itis possible to derive Eq 3 2 dT 7 mi Cp Tair T Eq 3 2 Where e m total mass of air in the box C specific heat at constant volume of air e m constant air flow provided by the fan heat at constant pressure of air T current temperature ins
3. 5 1 2 3 5 Chapter 2 Design specifications viii A 6 A ornai aa EA a a a sao RA A LES 6 2 2 Punctional specifications 7 2 3 Physical sp cificatiONS sancionadas 8 Chapter 3 Design analysis and 5 1 10 3 1 mobile cart and thermal systems lab 14 3 2 HVAC installation a 16 3 3 Controls demonstrated 20 3 4 Controller and SENSORS TE T UI UU T 33 3 5 Guide User Interface GUI rana 39 Chapter 4 Implementation a dia 44 AUECOASTUCAN 44 2M UI 51 4 2 1 TOCOM mobile Criada 51 4 2 2 uU GP 52 4 2 3 6 M O 55 1 2 4 Control systems id ander dai 56 4 2 5 Thermal systems labios 60 4 2 6 Controller Sensor Sosa RE 63 Report 4 2 7 Guide User Interface GUN ronda Ar 66 PETES Re 67 Part Il BUE ci cis ein DER Fn orm ci ro ie 68 69 Part III Appendix 72 Appendix A Controller senso
4. 0194010104010 Figure 3 9 PCB board The two relays will be powered by two transformers 24V each connected in series and plugged to the wall so that 48V are obtained This voltage produces enough heating in the coil and velocity in the fan to reach the requirements In short the analog inputs 0 1 2 3 AI0 AI1 AI2 AI3 and ground will be used to gather data from the thermocouples and the analog outputs 1 serve as the control signals for the coil and fan respectively Figure 3 10 shows all the possible connections in the analog part of the DAQ and the connections that are used are in red 4 Part I Report Pagina 23 ERS lt i s Sy Swa rnin 5 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Signal Signal Terminal Single Ended Mode Differential Mode lt Figure 3 10 DAQ Connections To make clear all the concepts developed below Figure 3 11 depicts the flow chart of the entire process Part 1 Report Pagina 24 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA Digital output m gt DAQ USB 6009 To relays 5 Set temperature Equal
5. 25 Figure 3 12 Simulink schematic 2 2122414112000001000000006060600 988080 27 Figure 3 13 PWM LabVIEW interface sis sccicnnnnnnnnannnannwnnnnmnnnninnt 31 Figure 3 14 LabVIEW programming COD ER E GU 32 Figure 3 15 PXC modul Mm 35 Figure 3 16 Siemens room temperature sensor and duct temperature sensor 37 Figure 3 17 Air quality sensor 37 Figure 3 18 Relative humidity temperature sensor 2 04 20 0 38 Figure 3 19 Variable Air Volume box Actuating Terminal Equipment 6 NE E T HNIC 38 Figure 3 20 Back and Home 5 22244010000 0 000000000 000000000 9 lt 42 Figure 3 21 Created points MENU cria 43 Figure 4 1 CAD rendering of the mobile 44 Figure 4 2 Photograph of mobile lab 2 9 45 Figure 4 3 Photograph of mobile lab featuring Siemens display 46 Figure 4 4 HVAC system construction ducts ecce eee eere eene eene 47 Figure 4 5 Heating Coll enclosure il 47 Figure 4 6 System in standard flow configuration 48 Figure 4 7 System in reheating configuration 49
6. The Humidity Temperature sensor reads both values and is connected to the analog input block 2 Both values are displayed on the screen of the sensor and can also be manually controlled via button 5 for temperature and button 7 for humidity T epe tl LEJ T pesen Product Terminal Equpment Controller jen Provided by Siemens Retail Cost 806 25 The Terminal Equipment Controller TEC allows for the establishment of the Floor Level Network FLN where the actuator is connected In addition this connection allows for some sensors to be connected to the FLN directly and connect to the Controller via the FLN Product Duct Temperature Sensors Provided by Siemens A Retail Cost 50 80 The Duct Temperature Sensor functions the same as any temperature sensor except the probe for measuring temperature is located on the end so that it can easily be Product Fan Provided by Siemens Retail Cost 49 99 The Fan for the Box is connected to a relay that is powered by the controller When the occupancy switch is turned on the controller powers the relay which turns the fan on This same signal tells the TEC to begin to tum the damper Figure 1 11 Design Page 3 Part III Appendix P gina 80 S S lt UNIVERSIDAD PONTIFICIA CO
7. mu mu 2 thaux theta mu dgn regulator parameters updating h thaux Sh0 thaux 2 State system matrix linearization A B C D linmod sistema stb all real eig A 20 Simulation with new parameters if stb yaux zeros size yaux else sim sistema tfin 1 2 1 yaux y sym sal sall sal2 ym sal error yaux ym end Vaux stb sqrt sum yaux ym 2 Nd end Parameters and target function outputs theta thaux thetha_parameters theta Vaux num th 1 den th 2 1 plant tf tf num den p plant tf Part III Appendix P gina 102 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Program design PID m control w0 dis afpi p Mf Fa Fr fa sol wmin wmax control Transfer function of the final controller w0 cross frecuency p transfer function of the plant Mf Phase margin grades Fa Phase advance grades Differential part Fr Phase delay grades positive Integral part fa Filter coefficient Sol 0 maximun K y 1 minimum K wmin Starting point to look for the w0 wmax Maximun point for 0 AP o o AP o o Design parameters Mf 130 Fa 10 Fr 5 fa 0 1 wmin 0 000001 wmax 100000 auxl mod 180 pi angle freqresp p wmin 360 180 Fa Fr Mf aux2 mod
8. Amplitude T Rate Time Jo Amplitude J Boolean 1 1 1 0 151 Lu Time Figure 3 13 PWM LabVIEW interface Part I Report P gina 31 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL high cutoff freq fh low cutoff freg fl Figure 3 14 LabVIEW programming In short Table 3 5 and Table 3 6 show the specifications and the corresponding design that the controls subsystems must meet Accurate integration of 4 USB thermocouples as inputs and 2 digital outputs components in the control system coil and fan Provide enough power to actuators fan coil dampers Use of relays Accurate control response Provide a PID controller as a reference to comparece it Part I Report P gina 32 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL with other controllers Interface that allows to introduce the controller parameters PWM parameters and the desired Intuitive interface using LabView temperature easily Table 3 5 LabVIEW specifications Provide a tool that identifies the File that calculates the parameters of the transfers transfer function of the system function s plant by using an iterative algorithm Provide a tool that gives the parameters and express
9. Testing successfully reached the expectations The PID controller that the file in Matlab gives has been tested and checked manually for the same specifications indicated above in Table 4 5 The sample lab guide that students will be performing can be found in Appendix Chapter 3 Finally both simulation and real system responses have been gathered and compared to ensure that the identification is accurate Both responses were exported to an excel file as shown in Figure 4 10 Part I Report Pagina 58 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Comparison real system LabVIEW simulation Matlab Simulation Matlab Real system LabVIEW Temperature C 100 150 Time sec Figure 4 10 Comparison real system LabVIEw simulation Matlab As it can be inferred from Figure 4 10 the approach to the real system made by the system identified is accurate The PID reference cotroller mentioned in chapter 3 was implemented to obtain these responses Kp 10 Ki 0 1 Kd 0 01 Both responses show a similar shape and reach the steady state at the same time but they present different rising times One of the possible causes of these differences may be an error in some of the parameters involved in the identification such as the convection factor or the dimensions of the coil mass volume etc Furthermore the fact tha
10. 180 pi angle wmax 360 180 Fa Fr Mf sol 1 if auxl aux2 gt 0 disp It does not exist solution for the interval specified control 0 if gt 1 1 180 fprintf The phase advance value must be less than f asin 1 1 180 control 0 return end while wmax wmin gt le 5 wmed wmin wmax 2 aux0 mod 180 pi angle wmed 360 180 Fa Fr Mf if aux0 aux1 lt 0 wmax wmed else wmin wmed end end Part III Appendix Pagina 103 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL 5 Control AFPI C s K 1 1 Ti s 1 Ta fa s s w0 wmed C 1 abs freqresp p w0 Plant s modulus if sol 1 2 tan Fa pi 180 sqrt 1 fa 2 tan Fa pi 180 2 fa else x 1 fa 2 tan Fa pi 180 sqrt 1 fa 2 tan Fa pi 180 2 fa x1 1 fa 1 2 tan Fa pi 180 sqrt 1 fa 1 2 tan Fa pi 180 2 1 fa end Ti 1 w0 tan 90 Fr pi 180 Pi value with 5 Ca C w0 sqrt 1 0 2 modulus integral plant STa 1 x w0 Ta x1 w0 SPD s variable D K Ca w0 Ta sin 1 180 cos Fa pi 180 Kl sqrt 1 1 2 sqrt 1 x1 2 Smodulus of K2 Ca K1 modulus Ks K2 Ti control tf conv
11. 3 3 and 3 4 final non linear system s schematic implemented in Simulink is shown below in Figure 3 12 Part 1 Report Pagina 27 AR CONVECTION FACTOR UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL CONTROLLER VOLTAGE TEMP ait_flowim_sit 2 coil_resistence ACTUATOR Figure 3 12 Simuling schematic model Integratori oil Integrator Gain Part I Report P gina 28 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Dynamic s initial parameters are calculated to run the simulation e Voltage 60 Tair 25 C Air mass of air in the box 0 15 Kg e Air flow m Using the set point in Table 4 3 14 75 CFM 0 008 Kg s Cv 1012 4 Kg K Knowing that the coil utilized is made of Nicrom density 840052 the m following values are obtained e M coil mass ofthe coil 30 gr coil specific heat constant of the coil made of Nicrom 450 T A Area of coil 62 83 cm e Coil resistance 10 25 Q Assuming turbulence air flow and forced convection the convection factor obtained is h 47W m C Thus the non linear system model brings the possibility to come up with a linear transfer function around the operating p
12. EQ OFF AND FIRE EQ OFF OR OCPY EQ ON AND FIRE EQ ON OR OCPY EQ OFF AND FIRE EQ ON THEN OFF FAN ELSE ON FAN Part III Appendix Pagina 75 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL A 2 Guide User Interface GUI Appendix Cue Welcome to TOCOM LAB ESI T Designed and Created by Brian Taylor William O Quinn James Cook James O Hara and David Morales Want to learn what control systems and how they operate Need to know how to save energy and money on heating and air conditioning bills Think the idea of building your own system seems to complicated Curious how alarms can save your property and even your life Leam this and more in the lab just click below to begin Special Thanks to our Sponsor SI E M E N S Figure 1 3 GUI Homepage Part III Appendix P gina 76 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL D Graphics Ft Ede View insert Dynamic Tools Window Help jej snis el aigi tv w TOCOM LAB LI coz 2 What is a Control System lt DESIGN3 1 i 4 t 2 control system is a mechanical optical or electronic system that is o used
13. Figure 4 8 Differential pressure 50 Figure 4 9 Probes connected to system and differential pressure gage 50 Figure 4 10 Comparison between real system and simulation responses 59 Appendix ri PATERE E REX REV nese VER skeen 72 Figure 1 1 Fire Pull switch program 74 Figure 1 2 Occupancy switch program flowchart 222 2 2 76 Figure 1 3 GUI homepage iss semet AA 76 Report Figure 14 do 77 Figure 1 5 Temperature sensors 2 4044 44000000 77 Figure 1 6 Duct temperature sensor 78 Figure 1 7 Humidity temperature readings ooocccconoocccccnononcnonononanoncnanoncnononananoncnanonos 78 Figure 1 8 CO2 sensors 79 Figure 1 9 Beginning Cr RF wou FERNER Sa SO TR NER SENE S EUR ER MEER 79 Figure 1 10 Design page 2 2200 etre Ure URN ERE ER 80 Figure 1 11 Design page 3 crore rper ee nn ae TORRE XE Teka gu a ia 80 Figure 1 12 Alarm Da ordi mda dain 82 List of Tables Table 3 1 Design description for mobile cart with enclosed environment 14 Table 3 2 design description for thermal systems 15 Table 3 3 HVAC specifications and
14. ELECTR NICA INDUSTRIAL which is easily accessible and readable to the user The block diagram for the Siemens display is shown in Figure 3 2 Temperature Sensor Ambient Air GUI Insight PXC Controller Humidity Sensor 4 Fire Pull Switch General Control Explanation Occupancy Switch Figure 3 2 Block diagram for siemes display A system layout diagram is shown in Figures 3 3 and 3 4 for the overall system Part 1 Report Pagina 12 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Monitor HVA Box Controller Comp Tower Figure 3 4 Picture of actual display Part 1 Report Pagina 13 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL 3 1 TOCOM mobile cart and thermal systems lab The mobile cart with onboard enclosed environment meets the specifications as shown in Table 3 1 Enclosed environment enabling temperature control Portable lab unit to be used throughout Loma Hall Stores and provides space for onboard computer used for control of subsystems Provides space for onboard HVAC and air recycling loop Provides space for demonstration of Siemens components Sealed box made of wood with door to facilitate sensor a
15. Hardware 707218C Home Depot 19 94 3in Locking Caster Wheel 2 Richelieu Hardware 70722BC Home Depot 23 94 174 11 Total System Cost NI USB 6009 4 National Instruments 779026 01 National Instruments 600 NI USB TCO1 Thermocouple 3 National Instruments 781314 01 National Instruments 297 00 Milwauki Thermocouple 3 Milwaukee 49 77 2002 Tool Barn 533 00 5920 Total System Cost Table 1 2 Parts list for HVAC components The overall budget in hardware components for the project was 10 193 67 The majority of the funding 9 263 67 was provided by Siemens Industry which included the computer and the components USD Associated Students AS also provided funding for the construction of the cart and wiring of the HVAC system Software To develope the Project the following programs have been required LaBVIE satan 1505 Matlab with Simulink 150 Part II Budget P gina 70 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Microssoft Office 2007 600 Final cost 900 In conclusi n the final budget adding labor hardware and software is Final cost 900 10 193 67 15000 26 096 67 Part II Budget P gina 71 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL PART III APPENDIX Part III Appendix Pagina
16. NI USB TC01 thermocouples that will be directly hooked up to the USB port on the computer These thermocouples will be placed inside the box so they will take an average temperature With regards to the output signal of the controller coil the DAQ provides very few power 5V and 5mA so it is necessary to get the power from another source Since the output of the controller is a variable signal a PWM block will be implemented and used in conjunction with a relay The PWM gets a variable voltage level by changing the width of the pulse D at the digital output Figure 3 8 D 50 D 20 D 80 H Figure 3 8 PWM As it was mentioned before the fan will be independently activated using a relay through one of the analog outputs of the DAQ The relays from Zetler used in all the actuators are a general purpose relay that can be used with a 5V microcontroller or control circuitry The coil draws 72mA when engaged and the relay can switch up to 2A at 30V or 1A at 125V A PCB board has been installed to ensure safety and reduce the number of wires used in the connections It will contain two slots for the relays and 8 pins for all the inputs outputs needed as it is shown in Figure 3 9 Part 1 Report Pagina 22 UNIVERSIDAD PONTIFICIA COMILLAS p Spy ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI S a INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL
17. and displays do in fact alert the user when they get past the set limit off acceptable ranges The VAV system turning on by a switch is tested by turning the switch and observing if the system has been turned on The temperature should change in the GUI when the switch turns on and to be sure that the system is functioning the display reflects that change in temperature The results show that the system does in fact respond to the switch when it has been activated The GUI itself needs to be user friendly and this is tested by having students and group members work through the GUI and take a survey to express what they liked disliked and suggestions for improvement After students took the survey their results showed that overall the GUI has attained its goal of being easy to navigate and aesthetically pleasing Some comments about improvement oriented around the need for a Home and Back button on each page the button layout on the first screen needs to be larger and the descriptions for parts text needs to be larger All these suggestions were taken into account and changes to the GUI reflect that input The surveys were administered on April 30 May 3 2011 to 17 engineering students and 3 non engineering majors Part I Report Pagina 66 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL References 1 F Luis Pagola Control Digital Unive
18. and turns on the HVAC system the fan in the VAV box and slightly rotates the damper in the VAV box The programs can be viewed the Appendix Figure 1 1 and 1 2 Chapter 1 3 5 Guide User Interface GUI The GUI subsystem is designed to allow any user to interface with the entire system and learn about control system with ease What separates the design of TOCOM lab from other controls laboratories is the ability to interact with the system via the GUI As a result the GUI must meet the following Part 1 Report P gina 39 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL specifications and the chosen GUI design to meet those specifications is listed below in Table 3 8 Display Temperature C02 and Humidity GUI has values displayed Display Alerts and Alarms Alerts and Alarms appear in GUI when triggered All font must be at least 14pt All descriptions of objects must have pictures included All background colors must be easy to see colors Blue Red Green Black White A home button and a back arrow included on every page with exception of first page Easily navigatable GUI Follow Ergonomic Human Factor standards for all graphs Added a switch that turns entire VAV system to on position Switch to activate VAV system through Insight Table 3 8 Specifications and Deliverables for GUI The first major design d
19. cap is placed on the reheat outlet see Figure 5 ENDCAP ON Figure 5 Open System Valve Configuration Part III Appendix P gina 89 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Check that power is supplied to the HVAC loop by ensuring the onboard power strip is switched to the on position Turn on the computer aboard the TOCOM Mobile Unit and open the control system in LabVIEW by opening the VI file via the following path Desktop gt gt TOCOM gt gt control_PID tocomlab vi Open the Thermal Systems tab to open the interface shown in Figure 6 This interface will be used to activate the control system and simultaneously monitor the instantaneous temperature and power measurements PID PWM Controlled Space Temperature Thermal Systems T1 Temp Inside Controlled Space Ploto Instant Power of the Coil 500 5 400 5 p 30 A 200 4 100 1 4 00 00 000 4 00 05 000 0 5 12 31 1903 12 31 1903 0 Time Time Temperature T2 Temperature at Inlet Instant power of the fan 50 1 45 0 75 0 5 0 25 0 0 25 2 5 20 1 0 75 4 00 00 000 PM 6 35 21 200 PM 12 31 1903 12 31 1903 1 Temperature uim Power un 1 1 1 Figure 6 Screenshot of LabVIEW interface The control system which provide
20. is also a Fire Alarm Pull Switch Fire Strobe Light and a Terminal Equipment Controller TEC Placed below this panel is a Variable Air Volume VAV box with an attached Actuating Terminal Equipment Controller ATEC that will turn the damper in the VAV box along with measuring pressure drops This information is sent to the PXC through the Floor Level Network FLN and Part 1 Report Pagina 2 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL the readings from the other sensors and buttons are wired directly into the of the previously stated information is to be displayed on the GUI The GUI is placed on the main computer also located on the cart The GUI is to be easily accessible and user friendly while also allowing a user to learn about the system s design 1 2 Problem definition The problem that this project is attempting to solve is to successfully implement a mobile lab with an onboard controlled environment to propagate knowledge critical to energy management and sustainability The mobile lab must facilitate its own transportation within the confines of the engineering labs in Loma Hall The lab which caters to more advanced users in the form of control systems and thermal systems labs must also be able to serve as teaching tool for the basics of control systems and associated devices for any person who interfaces with
21. students to measure and compare efficiency for HVAC operation with and without the recycling loop 4 Thermocouple T1 placed within the enclosed environment output and another T2 within the HVAC duct upstream of the fan Voltage supplied to each device know Power is collected real time using LabVIEW User observes differential pressure reading of airflow from this measurement mass flow rate through system calculated using provided equations and background on theory Table 3 2 Design description for thermal systems lab While the control system regulates the HVAC system to achieve a steady state temperature the thermal systems lab exercise can be completed The Part I Report P gina 15 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL lab handout describes the procedures for the collection of data conversion to SI unit system and calculation of desired values The temperature set points of the lab will not exceed 33 C for both system configurations These values were chosen based on time to reach steady state 3 2 HVAC installation This system is used to ventilate an enclosed environment and manipulate the temperature of the air The system utilizes a fan that pushes air over a heating coil to manipulate the temperature of the enclosed space The team designed a HVAC system that would meet th
22. the lab University of San Diego USD is increasing its sustainability campus wide demonstrating energy sustainability with an engineering controls lab will serve as yet another example of its efforts to increase sustainability 1 2 1 Customer Requirements The customers for this project USD students faculty and staff require a mobile lab that has the following characteristics 1 Measurements of the surrounding environment including temperature humidity and CO2 content of the air displayed on a GUI running on an onboard computer Part 1 Report Pagina 3 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL All components need to be visible and clearly identified to users interacting with the unit Safe mobile lab unit for future use by USD students faculty and staff Laboratory exercises which can be performed in both thermal science and control systems engineering using the mobile lab An easily navigable GUI conveying information concerning control system devices Physical Requirements The mobile cart unit will present unobstructed visual of air handling equipment control devices and other sensors All components need to be physically supported as well Since the mobile cart will be used as a teaching tool in different labs it must be mobile and able to fit in engineering labs and the elevator An onboard computer mus
23. to maintain a desired output i lane By using various components such as sensors and controllers we can create a control system that maintains a desired range of values CO2 Temperature Humidity Power Usage etc Using proper installation and coding we create ENERGY MANAGEMNT SYSTEM that not only mainatins those values but saves energy and money for the consumer View current sensor values below Want to learn more about how this system was designed Graphics TemperatureSensors ED View Insert Dynamic Tools Window Help osales lela al colo 20 ale lc rajo w IR Temperature Sensor 1 DESIGN2 DESIGNS 1 DUCT TEMPERATURE 1 FIRE 1 FIRST 2 HUMIDITY i HUMIDITY TEMPERA 1 TEMPERATURESENS WELCOME This Temperature Sensor is connected The Temperature Sensor sends it directly to the FLN and then sends its readings to the controller which readings to the controller Units are processes the information into the DEGF above graph Units are DEG F What temperature would you consider too hot too cold or just right In a Control System you always control temperature to your desired input Figure 1 5 Temperature Sensors Page Part III Appendix Pagina 77 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA IN
24. 22 2 365 74 1 PXX 485 3 Expansion Module 3 RS 485 Connections 908 45 908 45 302 82 1 TXS1 12FA 24VDC Supply 560 00 560 00 186 67 1 TXM1 16D 16 Digital Input Module 738 00 738 00 246 00 2 TXM1 6R M 6 Digital Output Relay Module w OVD 1 113 89 2 227 78 5742 59 1 TXM1 8U ML 8 Universal 1 0 Module w OVD amp LCD 1 569 75 1 569 75 523 25 2 TXM1 8X ML 8 Universal 1 0 Module w 4 20mA amp LCD 1 847 22 3 694 44 1 231 48 1 550 405 Actuating Terminal Equipment Controller ATEC VAV 806 25 806 25 268 75 1 540 100 Terminal Equipment Controller TEC 647 95 647 95 215 98 1 536 811 100K OHM TEC Thermistor Temperature Sensor 46 12 46 12 15 37 1 540 128 10K OHM TEC Thermistor Temperature Sensor 50 80 50 80 16 93 1 QAM2012 010 Platinum 1K OHM Duct Temperature Sensor 36 00 36 00 12 00 1 533 376 4 20 120 F 100 OHM Duct Temperature Sensor 4 20mA 155 45 155 45 51 82 1 QPA2000 CO2 Room Air Quality Sensor 0 10V 672 73 672 73 224 24 1 QFA3171D Room Humidity Temperature Sensor w Display 4 20 750 00 750 00 250 00 2 540 680FB TEC Room Temperature Sensor w STPT amp Display 177 17 5354 34 118 11 1 GDE131 1P Open Air Actuator 278 22 278 22 92 74 1 500 636173 Visual Strobe Light 69 12 69 12 23 04 1 141 0574 Air Flow Switch 05 1 0 WC 119 98 119 98 39 99 1 3VU69 Dayton AC 239 CFM Axial Fan 78 30 78 30 26 10 5 RH1BU AC24V SPDT 24VAC Relay w base 4 75 23 75 7 92 1 571 010 3P11 USB Insight Advanced Server 1 Use
25. 5 This controller has the capability to be expanded using Terminal Blocks or input output 1 0 modules with support for up to 500 1 0 points These points are for connecting sensors actuators switches and buttons The Terminal Blocks can be selected and added on to the controller based on the type of job needing to be accomplished Each block has different capabilities 6 7 Part 1 Report Pagina 34 Se UNIVERSIDAD PONTIFICIA COMILLAS P E gt 2 2 2 ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI 2 INGENIERO Y ELECTRONICA INDUSTRIAL Figure 3 15 PXC Module with Terminal Expansion Blocks The first block shown in Figure 3 15 block A is the power supply TXS1 12F4 for the 1 0 Modules It has 24 VAC volts of alternating current input used to power it and the expansion blocks The power supply also converts the 24 VAC into 24 volts direct current VDC to provide power for some of the sensors and other components that require DC The next module in Figure 3 15 block B is a 16 point digital input DI block TXM1 16D Refer to Appendix Table 1 1 Chapter 1 for input and output descriptions This module monitors normally open or normally closed dry contacts voltage free for up to 16 inputs The third block in the same Figure 3 15 block C is a digital output DO module with manual override TXM1 6R M This block provides six normally open or normally closed vol
26. 72 Vai 9 OW TIFIC R Ss a gt UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Appendix A Controller sensors and Guide User Interface appendix A 1 Controller and Sensors Appendix PXC controller has analog inputs to receive signals from analog devices i e sensors Temperature 02 and Humidity sensors are analog devices that output a linear 4mA 20mA or 0 10V signal analog PXC controller has dry contact digital inputs that detect if the circuit is completed from one contact to the other Buttons and switches output a dry contact digital signal when pressed or flipped PXC controller has digital outputs for ON OFF operation an enable relays Table 1 1 Description of inputs and outputs Part III Appendix P gina 73 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL NO Fire Pull Switch Triggered Turn on strobe light Turn off box fan Figure 1 1 Fire Pull Switch Program Flowchart This program represents what happens when a real wall mounted fire pull station is triggered in a building When the alarm is triggered a strobe light will flash and an alarm is displayed in the Insight software Point Declaration Type
27. 8 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL signal therefore requiring a DI on the controller The relays are connected to the dry contact DOs with 24 VAC feeding them from the transformer When the DOs are triggered the connection is closed and electricity from the transformer activates the coils on the relays The humidity and CO2 sensor vary current and voltage respectively so they both require Als on the controller The fire pull station consists of a button that is constantly depressed until triggered by a user When the user pulls the fire alarm the button is no longer depressed therefore creating a closed connection to a DI on the controller There are several programs written in Insight that are required to run some of the components on the Siemens display board These programs tell the controller what to do with the I Os For instance the Fire Pull Switch Program tells the controller to enable an output when it receives an input In other words when a user pulls the fire alarm the controller detects the input from the button on the fire station and enables the output to the siren as well as turns off the box fan to prevent the circulation of smoke The next program is the Occupancy Switch Program This program simulates a person walking into the room When the switch is flipped on the system knows someone is present
28. A COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL The Siemens Control Demonstration provides information on the installation and programming of control devices as well as real time data collection sensors and control devices through a graphical user interface The intention of the demonstration is to illustrate the critical components as well as the capabilities of control systems Finally the mobile lab unit can be transported between the electrical and mechanical engineering labs of the engineering building to provide both departments with a teaching tool for areas critical to energy sustainability Abstract Page 3 University San Diego ENGINEERING PROGRAMS TOCOM LAB Design of a controlled HVAV system to implement in thermodynamic and controls laboratories University of San Diego 2010 2011 Department of Engineering Final Design Report May 05 2011 Report Table of Contents Part oisi jError Marcador definido Chapter 1 Introduction irse cu iua iError Marcador no definido LAICO cci Error Marcador no definido A eala 3 1 2 1 Customer requirements 3 1 2 2 ASSUMPTIONS cepa av aue Eo TEN RE ER EVE ta EE ee eee Sa ea
29. ART I REPORT UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Chapter 1 Introduction 1 1 Context In an effort to encourage continued focus on energy management and sustainability the TOCOM group built a mobile lab unit which demonstrates efficiency and energy management building systems through the implementation of control systems Working with a leader in energy management Siemens Industry Inc the multidisciplinary team had the opportunity to learn how modern building technologies can be used to increase sustainability in operations and used this knowledge to develop the TOCOM Mobile Lab The project was divided into two sections Design and construction of an air control system for a small environment and a demonstration of the Siemens control devices The air temperature control system regulates the air temperature within an enclosed environment through the use of a miniature heater and fan actuated through LabVIEW The Siemens control demonstration uses control devices and hardware to show how to program and install real size sensors and display these readings on a Graphical User Interface GUI The two different sections will place their respective parts together on the cart and share a computer that will have Insight and LabVIEW installed on it Part 1 Report Pagina 1 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE
30. AUTOM TICA Y ELECTR NICA INDUSTRIAL SW 5 10 15 w NNCHES W C us Figure 4 Differential pressure gauge 3 Nomenclature Quantity Symbol Units SI Units Imperial Description Current flow of electric charge Voltage V V electrical potential difference Power P W rate of energy transfer force exerted on a container per unit Pressure p N m inch WC area volume which passes through pipe per Volumetric Flow Rate m s ft s unit time rate mass passes through pipe per unit Mass Flow rate m kg s slugs s time Density p kg m slugs ft mass per unit volume percentage of power retained from Efficiency n 96 96 input to outp t amount of heat required to change Specific heat kJ kg K Btu Ib 9R temperature physical property of matter relating to Temperature T K 9R thermal equilibrium Heat transfer e kJ kg Btu lb rate of heat transfer per unit mass kJ s Btu s rate of h at transfer per unit time Enthalpy h kJ kg Btu Ib total energy of a thermodynamic system Part III Appendix P gina 87 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL 4 Investigation of air temperature control system Objective To determine the efficiency of the system at steady state by comparing power input to heat output and to compare the efficiency of the reheat configuration to the open loop configuration Theory Efficien
31. DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL the end cap is removed thus allowing the air to be re circulated and reheated The reheat configuration is shown in Figure 4 7 Figure 4 7 System in Reheat Configuration The differential pressure gage is shown in Figure 4 8 through the clear wall of the cart The gage is mounted inside the enclosed environment and measures the differential pressure in the system Note Further information on the differential pressure gage can be found in both the Design and Analysis section and the Testing section Part 1 Report P gina 49 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL T s y NNCHES WC Figure 4 8 Differential Pressure Gage Lengths of clear tubing which are used as the probes for the differential pressure gage installed in the system and attached to the back of the differential pressure gage are shown in Figure 4 9 The metal pipe seen running into the PVC tubing is used to hold the total pressure probe parallel with the flow ofair Static Pressure Probe Total Pressure Probe Figure 4 9 Probes Connected to System and Differential Pressure Gage Part 1 Report P gina 50 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUS
32. DUSTRIAL Graphics IDoctTempereture Sensor Fite inset Dynamic Tools Window Coca lf mm e 28 ejr pre e Duct Temperature Sensor D The Duct Temperature Sensor which has been placed on the board sends the information to the PXC 5 DESIGNI DESIGNZ 2 DESIGN 2 DUCTTEMPERATURE 2 FIRST 2 HUMIDITY i HUMIDITY TEMPERA TEMPERATURESENS WELCOME Note Units are DEG F Graphics Humdity Temperaturel Edt View Imen Dynamic Tools Window Se aer feo je vel a me p Tna Temperature Humidity 305 07 1221230 ns IGN3 d OUCTTEMPERATURE innt 2 FIRST 2 HUMIDITY 2 HUMIDITY TEMPERA 1 TEMPERATURESENS WELCOME oo Teu SNR 02 TEMP 2502 The joint readings from the Humidity Temperature Sensor are displayed here Note Temperature is being Note Humidity is measured in measured in Celsius Figure 1 7 Humidity Temperature Readings Part III Appendix Pagina 78 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Graphics C02 Edit View Insert Dynamic Tools Window g
33. Description TCM SWT 01 FIRE LDI FIRE PULL SWITCH TCM ALM 01 FIRE LDO FIRE ALARM LIGHT SIREN 00010 C 00020 C FIRE PULL ALARM 00030 C 00040 DEFINE FIRE TCM SWT 01 FIRE 00050 DEFINE ALFIRE TCM ALM 01 FIRE 00060 IF FIRE EQ OFF THEN OFF ALFIRE ELSE ON ALFIRE Part III Appendix Pagina 74 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Is Occupancy switch on YES Turn Fan ON Rotate Damper 45 degrees Figure 1 2 Occupancy Switch Program Flowchart This program detects occupancy In order for the system to be used a switch will need to be flipped as if a person was to walk into a room or office When a person enables the occupancy switch the fan in the VAV box turns on and the model damper starts rotating to simulate the HVAC system responding the environment If the Fire Alarm is enabled then the fan shuts off to prevent smoke circulation Point Declaration Type Description TCM AH1 01 DMPR LAO MODEL AIR HANDLING DAMPER 5 02 LDI OCCUPANCY SWITCH 01 LDO VAV BOX FAN 00070 C 00080 SWITCH 00090 00100 DEFINE DMPR TCM VAV 02 DMPR Define Variables variables called in other programs do not need to be called again i e FIRE 00110 DEFINE OCPY TCM SWT 02 OCPY 00120 DEFINE FAN TCM VAV 01 FAN 00140 IF OCPY
34. Figure 4 2 and 4 3 Figure 4 1 CAD Rendering of the TOCOM Mobile Lab Part I Report P gina 44 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Figure 4 2 Photograph of TOCOM Mobile Lab air control system and HVAC system Part I Report Pagina 45 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Figure 4 3 Photograph of the TOCOM Mobile Lab featuring Siemens Component Display HVAC System Construction The main body of the HVAC system through which the air travels is made of PVC tubing All tubing was purchased in two feet lengths and then cut to size using a horizontal band saw Pipe cement was used to connect some portions of the system while others were pressed together to allow for disassembly and maintenance Figure 4 4 shows a computer model of the entire system This figure was chosen over a picture of the physical system because the system cannot stand free on its own Part I Report Pagina 46 ERS 2 i s Sy Swa rnin 5 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI lt INGENIERO AUTOMATICA ELECTRONICA INDUSTRIAL Figure 4 4 HVAC System construction ducts The heating coil enclosure made of abs tubing is shown in Fi
35. INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Both groups must be aware of the size of each other s components and to ensure that the display is not only functional but easily accessible Air Control System An enclosed environment was constructed aboard the cart to contain the air to be conditioned by the control system The control system and heating ventilation and air conditioning HVAC system integrated with the enclosed environment will enable the TOCOM mobile lab to be used for both thermal systems and control systems laboratory exercises The thermal systems laboratory focuses on comparing the system efficiency when air is directly taken from the outside environment or re circulated within the system The efficiency can be analyzed through the calculation of heat and power input values based on real time measurements The control systems lab focuses on the design of control systems using the physical actuators and sensor devices aboard the cart Siemens Control Demonstration The Siemens control demonstration portion of this project was developed with the help of Siemens Industry Inc The Siemens display will feature a Programmable Controller PXC that is the main processor for all information generated in the Siemens lab On the cart a group of sensors for Temperature Humidity and carbon dioxide 02 are to be placed on a display panel so that they can be easily seen On the display panel there
36. K2 Ta K2 Ti 1 Ta fa 1 01 parallel version nu 1 1 fa Ta Ti Kp Ks nu Ip nu Ti Dp 1 nu fa Ta 1 nu fa 1 return Part III Appendix P gina 104 UNIVERSIDAD PONTIFICIA COMILLAS JTW ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI 22 lt INGENIERO AUTOMATICA Y ELECTRONICA INDUSTRIAL Appendix D Plans D 1 Cart assembly dimensioned plan N21 D 2 HVAC installation plan N22 Part III Appendix Pagina 105 AS 74 gt gt Es UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL CART ASSEMBLY AUTHOR JAMES 4 Part III Appendix Pagina 106 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL SCALE 0 300 Part III Appendix Pagina 107 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Design of a controlled HVAC system to implement in thermodynamics and controls laboratories David Morales Gal n Madrid Junio de 2011
37. MILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Alarm View Help _ fa z B sive BUN oco Ack Initial Current Status Priority Ack By MEE Point Name Value Initial Current it OFF 10 28 46 10 16 339PM Ne NONE Time Date Trunk aaa aaa Building Level Network Messages ofl W QutofServ Normal 92245 AM E Failed 0058 PDSB W PRI2 O O PAIS E W PRI For Help press Fl Beep Sort DES TIME Figure 1 12 Alarm page Pagina 81 Part Appendix UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Appendix B Thermal Systems Lab users manual Table of contents 1 INTRODUCTION Ea aa eana 3 2 EQUIPMENT 4 3 NOMENGCLATURE 6 4 INVESTIGATION OF AIR HEATING 7 A Pat o oo A 8 tet 11 1 5 RESTS M DNI M CE M E 12 A A 12 5 EXPERIMENTER CHECK LS Tiana 13 5 1 Thermal system lab survey form 14 Part Appendix P gina 82 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPE
38. N AUTOMATICA Y ELECTRONICA INDUSTRIAL Por otro lado el dispositivo m vil contiene ademas una demostraci n de los sistemas de control de Siemens Ver Figura 1 1 con la intenci n de mostrar sus funcionalidades y capacidades Dicho sistema incluye su propia Interfaz Grafica GUI la cual muestra al usuario de una forma intuitiva y facil la informacion de los sensores y demas aparatos de control Por ltimo el dispositivo m vil puede ser transportado f cilmente la totalidad de las instalaciones del edificio de ingenier a de la Universidad de San Diego con el fin de ser una herramienta til en las reas relacionadas con la sostenibilidad Resumen P gina 3 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL ABSTRACT With the assistance of Siemens Industry Inc the TOCOM Lab demonstrates energy sustainability through the implementation of control systems and associated devices in a lab environment A mobile lab unit was constructed to contain an onboard air control system and display a configuration of control system devices and instruments The mobile lab unit is shown in Figure 1 1 Monitor Box 4 Controller Figure 1 1 Mobile lab unit design An enclosed space within the unit serves as a model environment in which a control system will regulate the air temperature A computer actuated air control syste
39. RIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL 1 Introduction The TOCOM Mobile Lab unit uses LabVIEW to run a control system which regulates the air temperature in an enclosed environment In the following experiments the air temperature control system will be used to provide a steady state temperature within the enclosed environment Increased efficiency is a primary motivation for many engineering applications By taking temperature differential pressure and electrical power measurements the efficiency of the air temperature control system can be calculated The objective of the following experiment is to analyze and compare the efficiency of 1 an open loop heating system 2 as well as a heating system using reheat or a recirculation of the heated air through the system Part III Appendix Pagina 83 Se UNIVERSIDAD PONTIFICIA COMILLAS gt 2 2 ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI Y 9 INGENIERO Y ELECTRONICA INDUSTRIAL 2 Equipment Description The air temperature control system is physically composed of the enclosed environment and the HVAC System seen in Figure 1 Computer Monitor Controlled Space Figure 1 HVAC System diagram The control system allows the system devices fan motor and electric resistive heating coil within the HVAC loop to be activated and configured through the LabVIEW
40. TRIAL 4 2 Testing 4 2 1 TOCOM Mobile cart The TOCOM Mobile Cart was tested in a few specific areas concerning mobility and support of onboard subsystems The testing method and results are outlined in Table 4 1 Enclosed environment enabling Temperature increase without gross temperature control loss of heat input Portable lab unit to used Maintained assembly and mobility throughout Loma Hall while moving through Loma Hall Stores and provides space for Al computer components onboard computer used for function and be interfaced with control of subsystems Provides space for onboard HVAC Observe that HVAC system and air recycling loop functions in the provided space Siemens components fit within the Provides space for demonstration allotted space allowing easy access of Siemens components for demonstration Table 4 1 Testing Methods and Results for Mobile Cart The primary focus of the testing for the TOCOM Mobile Cart was on mobility The cart was moved through engineering laboratories and onto the elevator in the building the successful transportation of the lab shows that the requirement is met Part I Report P gina 51 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL The design of the system accounted for the space needed by the supported subsystems this requirement was met upon the completion o
41. UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL PROYECTO FIN DE CARRERA DESIGN OF A CONTROLLED HVAC SYSTEM TO IMPLEMENT IN THERMODYNAMIC AND CONTROLS LABORATORIES AUTOR David Morales Galan MADRID Junio de 2011 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL RESUMEN DEL PROYECTO Con la ayuda de Siemens Industry Inc este proyecto apuesta por la sostenibilidad a trav s de la implementaci n de sistemas de control Una plataforma m vil ha sido construida con el objetivo de contener un sistema de control de calefacci n de aire y una interfaz que muestre los par metros de configuraci n del controlador implementado y la respuesta del mismo La Figura 1 1 muestra el dise o de dicha plataforma Monitor Box Controller Comp Tower Figura 1 1 Dise o de la plataforma m vil con el sistema de control Un peque o compartimento dentro del dispositivo m vil funcionar como la planta del sistema en la cual el controlador deber de regular la temperatura del mismo El sistema de control de aire introducir aire caliente o a Resumen P gina 1 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL temperatura ambiente para calentar o enfriar el c
42. UTLET Figure 8 Closed System Valve Configuration Repeat Part A with the closed configuration of the HVAC loop Part III Appendix Pagina 93 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL 4 3 Results Results for the collected data should be recorded in a table like the one shown below AT Trial T1 2 Ah Ap m Qin Pin n 1 2 inch ie ie K kJ kg We kg s kJ kg kW For near room temperature air consider the following constant c 1 005 kJ kg K and p 1 1614 kg m3 Note that the specific heat of air and density required for the calculation is assumed to be constant due to the relatively small change in temperature Recall that 1 kJ s 1 kW 4 4 Conclusion Compare the efficiencies from Experiment A with those from experiment B Comment on the cause of any differences between the two data sets Part III Appendix P gina 94 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL 5 Experimenter Check List Procedural Outline Part Investigation of air heating system a Constant values i Power for the fan provided in LabVIEW ii T2 Temperature at inlet room temperature iii Differential pressure can be viewed through window to controlle
43. a hair dryer s heating element because of its fast response time and small size While taking the hair dryer apart the team realized the small inline fan contained with it was an ideal fan for the HVAC system The fan is almost three inches in diameter and thus fits inside the three inch diameter ABS tubing By testing the system with the fan and heating coil installed and working the team was then able to determine a proper flow rate If the flow rate is too low the system will not react quickly enough and heating coil may over heat If the flow rate is too high the air passing over the heating coil will not get hot enough to adequately heat the enclosed environment The team was able to find a range of flow rates that worked for the system For more information on the flow rate please see testing section Chapter 4 A differential pressure gage has been installed into the enclosed environment Total and static pressure probes coming from the differential pressure gage are installed into the HVAC system at the same location shown Part I Report Pagina 18 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL in Figure 3 6 after the fan and heating coil housing The total pressure probe is installed parallel to the airflow using a metal rod to hold it straight The static pressure probe is installed perpendicular to the direction of airflow The differe
44. argins of at least 30 distance of Provide a tool that gives the wyand wo from x y axis parameters and expression of a certain e Quickest settling and rise PID controller for specific time for these limitations requirements Test the real system Pass simulation for different values of the PID controller Bring the possibility to export the results in Matlab to Labview and see the differences between simulation and real system Attempt of the team members to Pass Friendly guide to do the lab do the lab in their own Table 4 5 MATLAB Specifications and Testing Part I Report Pagina 57 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL The plant of the system is an integrator affected by a non linear effect of the actuator This means that the response tends to be infinity in open loop so it is necessary to close the loop and proceed with an identification of the plant The file that originally was developed for the linearization was based on the commands trim and linmod in Matlab but unfortunately they can only be applied to stable systems in open loop To correct this problem a new file was created so it has been possible to do the identification It is based on the application of an iterative algorithm that solves the parameters of the transfer function for a given input output obtained from the non linear system simulation
45. ccess Cart wheels supports onboard subsystems dimensions within elevator and door constraints Space provided for computer tower monitor DAQ and other components aboard cart HVAC loop installed and functioning onboard cart Backboard constructed on cart for placement of components and concealment of wires Table 3 1 Design description for mobile cart with enclosed environment The cart is currently constructed to meet the specifications described above The cart meets all functional requirements the accommodation of other subsystems is described in the testing section Chapter 4 The dimensions and further documentation can be found in the plans attached Part I Report Pagina 14 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL By following the lab procedure found in Appendix Chapter 2 students can investigate and compare the efficiency of an air temperature control system to a similar system utilizing an air recirculation loop The thermal systems lab meets the required specifications as seen in Table 3 2 Thermal systems lab will enable students to compare power savings due to recycling loop Temperature readings before and after addition of heat Ability to measure power provided to fan and heating element Ability to measure volume airflow through the system Lab handout directs
46. ch that when it is closed the air is redirected back through the system when the cap is removed A digital model from ProE of the system denoting the locations of the valve and end cap can be found in Figure 3 5 Exhaust Valve End Cap O A Figure 3 5 Valve and End Cap Locations Part 1 Report P gina 17 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL The HVAC system s piping valve and cap were purchased assembled and installed together The fan and heating coil have also been acquired and installed into the system The fan and heater are mounted into black ABS housing sections using an adhesive pipe insulation which is rated for temperatures up to 76 7 C ABS was chosen as the housing for the heater because of its high heat tolerance and availability PVC was used for the remaining sections of the systems piping because of ease to assemble and available sizing The entire HVAC system has been mounted on the cart and connected to the contained space The inlet and exhaust pipes extend into the contained space to facilitate the circulation of air through the space In order to properly heat and ventilate this system a constant flow rate is needed The control system varies the heat applied to the flow in order to manipulate the environment The heating coil used in the system was taken from a hair dryer Initially the team decided to use
47. change in pressure indicating a change in flow rate Run the system at its maximum allowed temperature set 33 degrees Celsius Using the reading from the thermocouple determine if the system reaches the set temperature Heating element contained inside ABS piping which is rated up to 76 7 degrees Celsius which exceeds the elements maximum temperature Run the system at its maximum allowed temperature set 33 degrees Celsius Observe system to see if any deformations form Note PVC piping is rated to 60 degrees Celsius System designed to fit inside and on cart 25 x 50 x 32 System was built and then installed onto the cart Test valves first by turning red handles to ensure they rotate a full 90 degrees Then conduct Thermal Systems Lab written for this lab equipment Table 4 2 HVAC Testing Part I Report Pagina 53 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL To test the ability of the HVAC system to provide a constant flow rate the team ran a series of tests using ten different user specified temperatures in LabVIEW Each test took a different amount of time because the system had to reach a different temperature each time Once a test began a team member watched the differential pressure gage If the reading on the gage had changed it would have indicated a change in flow rate In each of the tests the readings from the dif
48. cy of the heating system can be described by EQ 1 n Fa EQ 1 In this case the Qout is the rate of heat transferred to the air by the HVAC system The Pin is the electrical power added to the fan and resistive heating coil The total electrical power can be calculated with EQ 2 Protal EQ 2 The rate of heat added to the air in the system can be expressed by EQ 3 Q rn Ah Mass flow rate be calculated using differential pressure some system performance dependent constants The calculation can be performed directly using EQ 4 in Gp 72x 10 5 EQ 4 where Ap is the differential pressure inches W C The mass flow rate is in SI units If the assumption is made that the air in the system is incompressible can be modeled as an ideal gas the relationship described in EQ 5 can be used This assumption is appropriate for this system s analysis Part III Appendix Pagina 88 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Ah EQ 5 By substituting EQ 2 3 4 and 5 into EQ 1 we find the equation for efficiency described in EQ 6 6 n Ptotal Q Method 4 1 Part A Investigation of air heating system Ensure the system geometry is in the open configuration by checking that the exhaust valve is open and the end
49. d space b Steady state values to collect i T1 Temperature in the controlled space 1 Use average value of data collected for calculations 2 Should be fairly constant for steady state ii Power used by heating coil use average value of data collected for calculations c Calculate efficiency with the equations provided II Part B Investigation of reheat in air heating system a Constant values i Power for fan provided in LabVIEW ii Differential pressure can be viewed through window to controlled space b Steady state values to collect i T4 Temperature the controlled space 1 Use average value of data collected for calculations 2 Should be fairly constant for steady state ii 2 at the inlet 1 Mix of exhausting room air with room air 2 Should be a fairly constant median value Power used by heating coil use average value of data collected for calculations c Calculate efficiency with the equations provided Part III Appendix Pagina 95 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL 5 1Thermal Systems Lab Survey Form TOCOM Mobile Lab Thermal Systems Lab Survey Form Answer the following questions regarding your analysis Final efficiency for open system without reheat Final efficiency for system with reheat Please answer the following statements yes no Were you able to
50. e acquisition thermocouples and transmission of control signals through the DAQ See if the values Accurate integration of components in gathered in LabView match with the control system the real values Implementation of two Pass transformers that provide 48 and 24 volts to power coil and fan Test Provide enough power to the actuators of the appropriate running of the fan coil components pipes coil fan Test the reference PID controller Pass and see if it achieves the requirements effectively Accurate control response controls the temperature Distribute a survey to students 9 10 and and receive feedback Intuitive interface using LabView Table 4 4 LabVIEW Design Specifications and Testing 4 2 4 Control systems lab The controls lab has been tested separately from the overall controls systems and the results are seen below in Table 4 5 Part 1 Report Pagina 56 ONTIF I LG a Swa rnin R Es gt z gt INDUSTRIAL UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA Compare the outcomes of the Pass linear and non linear system and Provide a tool that identifies the see if they are reasonable less transfer function of the system than 10 error between them Test the for the Pass following requirements Overshoot of 20 e Stability m
51. e specifications and the corresponding design requirements as shown in Table 3 3 Fan controlled by LabVIEW verified by Provide a constant measurable taking pressure readings from a flow rate 14 7 CFM differential pressure sensor Controlled heating element obtained Ability to heat air from room from hair dryer designed not to exceed temperature to 37 5 C 60 C Heating element contained inside ABS System withstands temperature piping which is rated up to 76 7 C which of heating element exceeds elements maximum temperature System designed to fit inside and on cart System fits inside cart 25 x 50 x 32 Part I Report P gina 16 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL System must be able to run both Piping valve and cap are arranged in standard and re circulation such a way that the system can exhaust flow the air or re circulate the air Table 3 3 HVAC Specifications and Design The layout of the system was designed to fit within the dimensions of the cart The scale drawings of the system can be found in plans attached The system layout found in Figure 3 3 is to scale and also shows HVAC system installed on the cart When the system is set for a recirculation process the exhaust valve is closed and the end cap is removed The exhaust valve is placed su
52. ecision was what program to run the GUI on to satisfy all requirements There are many options that were explored and in some cases created to evaluate which program should be used Simulink MATLAB However for all the sensors to be integrated with the GUI the program that should be used is Insight a Siemens created program Insight displays all sensor values on a series of graphs along with the ability to manage the overall system While Insight was chosen to create the GUI it also had drawbacks that needed to be modified for the program to accomplish all goals outlined Part 1 Report Pagina 40 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Insight s major drawback was that it was designed for Siemens employees and not meant to be user friendly The program is built to store information and allow anyone with knowledge of Siemens programming to access the system This was not acceptable as the GUI needed to be easy to use for anyone not just those with an intimate knowledge of Insight The solution was found in Micrografx Designer a program that interfaces with Insight that allows for pictures diagrams schematics and other more user friendly data to be uploaded Now with the chosen programs in place the first step in the design was to create a format that allows the system to be easily navigable and also outline areas where sensor read
53. en the ventilation system needs to cycle fresh air throughout the enclosed environment Figure 3 17 Air Quality Sensor CO2 Relative humidity can be measured using the sensor in Figure 3 18 QFA3171D This high accuracy device can measure temperature from OC to 50C 32F to 122F and relative humidity from 0 to 100 The device outputs Part 1 Report Pagina 37 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL a signal of between 4 to 20 mA for the temperature and relative humidity levels Figure 3 18 Relative Humidity Temperature Sensor To actuate the damper in the model Variable Air Volume VAV box shown in Figure 3 19 an Actuating Terminal Equipment Controller ATEC is used 550 405 This unit contains an actuator that controls a damper as well as has two Als and two DOs for other components The controller also features a high low pressure differential sensor and a connection for a room or duct temperature sensor Figure 3 19 Variable Air Volume Box Left and Actuating Terminal Equipment Controller Right Wiring the components depends on the different types of signals being outputted to the controller All the temperature sensors work by varying resistance which requires an AI on the controller However the override button on the room temperature sensor unit sends either a high or a low Part 1 Report Pagina 3
54. es fan Fire pull switch program disables Pulled fire alarm Pass fan when pulled ATEC moves the damper in the Command the ATEC to rotate the VAV box damper 50 Pass Multiple people of different 4 5 people gave Sensors visible to all users heights viewed the system passing score Table 4 8 Controller and Sensor Testing The room occupancy switch was tested in a very similar manner as the fire pull switch A program was created that enables the appropriate variable Part 1 Report Pagina 63 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL when the switch on the sensor backboard is triggered This program is similar to that of the fire pull program so it also worked on first try The next test was tougher to get a positive result due to being slightly more complex The first dozen tests failed due to the code The variables and installation were all correct however the code structure was more difficult to understand due to the old FORTRAN based code The conditional statement had to be aware of multiple scenarios instead of the conventional single scenario The controller needed to be able to differentiate whether the fan was on when the fire alarm was triggered In real life situations if the fire alarm is triggered in a building the system shuts down the HVAC system so that smoke is not distributed throughout the ven
55. etrieved Figure 3 21 Created Points Menu With the pages built and sensors integrated we created alarms for each sensor to message the user if the values are out of acceptable ranges For example if the reading for the CO2 sensor exceeds 600 parts million an alarm appears on screen informing the user that the value is too high An example of what the user observes can be found in Figure 1 12 Appendix Chapter 1 The next specification says that a shutdown button occupancy switch should be able to turn the system on and off This means that a switch is placed on the board that when turned to the on position the VAV begins to push air through the system and when turned to the off position no air flows through the system To meet this goal a switch is placed in the system that when turned on causes the VAV to turn on When turned on the VAV box begins to turn the damper and the fan switches on The temperature sensor in the VAV also changes values which are displayed on the screen Part 1 Report Pagina 43 S UNIVERSIDAD PONTIFICIA COMILLAS d ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI v N hann INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Chapter 4 Implementation 4 1 Construction The TOCOM Mobile Cart has been constructed to the design specifications described earlier The CAD rendering of the unit with primary components of all systems is shown in Figure 4 1 The completed construction is shown in
56. f construction All components for the other subsystems fit on the cart and were positioned to facilitate user interaction The integrity of the enclosed environment has been confirmed by the successful addition of heat into the air within the system without excessive heat loss enabling the control system to achieve a steady state temperature Heat loss within the system was unavoidable and necessary to achieve steady state at an elevated temperature Achieving the steady state condition at an elevated temperature demonstrates the functionality necessary for the thermal systems and control systems lab exercises An excessive loss of heat would have prevented the system from reaching an elevated temperature indicating leakage of the air in the enclosure Efficiency of the system was revealed in the testing of the thermal systems lab 4 2 2 HVAC Throughout the project the team has continuously tested and adjusted the design and parameters of the HVAC System The system configuration has been redesigned a total of four times The first system contained automated valves but through testing it was determined that the system could not achieve the necessary pressure for the valves to function properly The second system was a similar layout to the first but contained all hand actuated T valves requiring manual system adjustment As testing was conducted on this system the team found that the fan being used could not withstand the high temperature o
57. f the exhaust at the inlet and as a result the team burned out a fan The team then designed a system utilizing a Daton AC Axial Fan which could tolerate a high inlet temperature Although the fan was rated for 115 cubic feet per minute CFM flow team found through testing Part I Report Pagina 52 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL that the fan did not provide a measureable pressure differential as required by the labs The finalized HVAC design uses a hair dryer fan at an open inlet and utilizes an open air mixing process for the exhaust allowing for a lower inlet air temperature during a reheat cycle To test the finalized HVAC system design the team took the customer requirements and developed testing procedures for each one to evaluate the team s level of success Table 4 2 below outlines the requirements testing procedures and resulting outcome from each test Ability to provide a constant measurable flow rate Ability to heat air from room temperature to 33 degrees Celsius System withstands temperature of heating element System fits inside cart System must be function as both standard and reheat flow Conduct a series of tests in which the system 15 run using different temperature specifications set in LabVIEW During tests observe the differential pressure gage to determine if there is a significant
58. ferential pressure gage remained constant and thus the flow rate remained constant During these tests the team was also adjusting the amount of power provided to the fan The team found that at very high speeds the controlled environment would not heat up because too much air was running over the heating coil rendering it ineffective When the fan was running too slowly the heating coil would begin to get too hot During one of the tests the team burnt out a heating coil because there was not enough air flowing through the system The team determined that the fan powered at 24 volts provides a flow rate of 14 7 CFM through the system This flow rate allows for the system to react quickly while not flooding the heating coil with too much air The operator verified before testing the system that the valve and cap worked properly When testing for the maximum temperature the system could achieve the team found that that the system in the reheat configuration achieved a higher maximum temperature than the system could in the standard flow configuration The maximum temperature the system can achieve for the reheat configuration was found to be 37 5 degrees Celsius The maximum temperature the system can achieve for standard flow was found to be 35 75 degrees Celsius The team decided that for the lab there should be a cap on how high students can set the temperature that does not reach the maximum the system can achieve thus in the lab the highest te
59. g for the efficiency analysis of both the open and closed system configurations Thermocouple sensors were properly installed and interfaced with LabVIEW enabling users to collect and view the temperature measurement data The reading was initially found to be inaccurate by 3 but it was calibrated using a thermocouple heat meter The sensors one measuring upstream of the heating element and one inside the controlled space provide a temperature differential which is acquired and recorded by LabVIEW The Part I Report Pagina 61 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL power provided to the system fan and heating element is also recorded in LabVIEW Upon testing the lab exercise the users were able to extract all data required for the efficiency analysis Mass flow rate of the air through the air temperature control system is calculated from the differential pressure gauge measurement Though this was possible upon testing the lab it was discovered that the lab handout did not include the equation for mass flow rate calculation from a pressure differential This created a problem as the lab exercise could not be completed using only the lab handout as a reference necessary corrections were made to the lab handout The objective of the thermal systems lab is to compare the performance of the two system configurations by a
60. gather all of the required data If not what data was not collected Approximately how long did it take for you to complete the lab Please individually rank the following statements 5 Highest to 1 Lowest Based on your background you are prepared to complete an efficiency analysis of a thermal system 5 4 3 2 1 The lab handout was easy to follow 5 4 3 2 1 The lab handout contained all necessary information 5 4 3 2 1 96 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL The user interface facilitated data collection and observation 5 4 3 2 1 The mobile lab is a useful tool for studying thermal systems 5 4 3 2 1 Part III Appendix Pagina 97 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Appendix C Controls system lab users manual C 1 Users manual 1 Objectives The main goal of this lab is to provide a tool that enables students to compare the time response and behavior of a real HVAC system and the corresponding simulation To accomplish this objective the student will go through the entire process of controllers design start from a non linear system obtain the equivalent linear model transfer function and final design of Proportional Integrative Derivative PID con
61. gure 4 5 the system is mounted onto the wooden cart The brown wires running into the tubing are used to power the heating coil housed inside F ieee Figure 4 5 Heating Coil Enclosure Part 1 Report Pagina 47 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Fan and heating coil used were mounted into the system using an adhesive insulation tape The heating coil came incased in a heat shield not shown The adhesive tape was wrapped around the circumference of each device and then installed into the ABS tubing The PVC tubing was used as the main body of the system The valve and cap were also made of PVC The valve cap and ABS fan housing are shown in Figure 4 6 The system in this figure is in the standard flow configuration meaning the system would be taking in outside air circulating it through the system and then dumping back into the outside environment if it were running In this configuration the exhaust valve is open while the end cap is attached The end cap prevents hot air from running back through the system Figure 4 6 System in Standard Flow Configuration In a reheat configuration the system re circulates air from the box some of the air from the box In this configuration the exhaust valve is closed while Part 1 Report P gina 48 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR
62. he first block as it is a digital output After being pulled the alarm sends a signal to the controller that when Figure 1 9 Beginning Page Part III Appendix Pagina 79 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL View Inset Dynamic Tools Window x fee aas oz eje mee vi Bu The Sensors 1 coz AE DESIGNT 2 DESIGNZ Provided by Siemens E Product Temperature Sensor m l Retail Cost 155 45 it DESIGNS DUCTTEMPERATURE FIRE e 2 HUMIDITY TEMPERA lt TEMPERATURESENS 2 1 WELCOME The Temperature sensor is connected to the FLN via an ethernet cable or wired directly into the PXC As with all sensors its values are sent to the controller for evaluation Notice how this temperature sensor has a Day Night mode that can be manually selected by pressing the button on the front of the sensor Product CO2 Sensor Provided by Siemens Retail Cost 672 73 sensor is connected to analog input block 2 and so its value can be read directly from the top of the controller The sensor can also be controlled manually through the top of the controller by pressing button 1 which is where the sensor is plugged into Product Humidity Sensor Provided by Siemens Retail Cost 177 17
63. ide the box e Tair temperature of the outside air 25 degrees Celsius Amount of heat provided by the coil through convection Assuming no losses the convection equation 3 gives the total amount of heat transmitted to the air which depends on the temperature of the coil area of the coil and the convection factor hconv Aconv Tair Eq 3 3 A third equation which gives the relationship between power applied to the coil temperature of the coil and heat transmitted to the air is needed to complete the dynamics 12 A AT coi x 2m Eq 3 4 Where Average power after PWM u voltage applied x T period Part I Report P gina 26 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL M mass of the coil specific heat constant of the coil It is important to remember that the use of PWM in the actuator introduces non linearities so this model brings the possibility to develop new controllers by finding and setting the operating point and getting a linear model Once the linear model is obtained it is possible to study the frequency response starting from the transfer function and design another controller which will make the system obtain the different specifications The set point that has been chosen is 28 C for the temperature inside the box Using Eq 3 2
64. ing each with adequate space while allowing for user interaction with the onboard computer system Part 1 Report P gina 8 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL The HVAC system was designed to house and insulate a heat source and fan The circuit is constructed of both Acrylonitrile Butadiene Styrene ABS and PolyVinyl Chloride PVC plastic tubing The inlet and exhaust to the enclosed environment are both 1 inch in diameter The heater and fan housings are each 3 inches in diameter with variable diameter steps interfacing the two different tube sizes The HVAC system safely provides the heated air necessary for the lab exercises Part 1 Report P gina 9 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Chapter 3 Design analysis and results Once the specifications have been set this chapter tries to give a technical description of the design process for each subsytem First a general description of the main systems Air control system and Siemens demonstration will be presented before going through the different subsystems that comprise the project With regards to the HVAC system implemented the small scale model of a real air temperature control system is composed of enclosed environment and the HVAC loop The valve actuato
65. ings could be displayed along with all other relevant information To make sure the GUI could be used with ease the following rules were applied to the design Now that these criteria had been established the GUI homepage was created as seen in Appendix Figure 1 3 Chapter 1 The rest of the pages were built with the next page called First that shows all the different sensors and gives links that navigates to each sensor s reading Refer to Appendix Each sensor page has the current value displayed and if the user wishes for a larger window they can click on the image Also on First is a link to the Design page which is created for a more in depth understanding of the system The Design page outlines each individual component including a picture description price and how it was incorporated in the lab The purpose of these pages is to show an engineer how the system was built and how they could replicate the design in a system that they would build The design pages can be found in Figures 1 4 1 11 of Appendix Chapter 1 Part I Report Pagina 41 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Once all pages were created a new problem surfaced navigating through the pages Any person who has experience with Insight found this process easy but when a sample of students were shown the GUI as it was at that time no
66. ion of a certain PID controller for specific File that provides the parameters of the PID controller requirements given the different specifications Bring the possibility to export the results from Matlab to Labview and see differences between simulation and real system Intruduce a file that exports data to an excell file Table 3 6 Controls lab specifications Part I Report Pagina 33 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL 3 4 Controller and sensors The controller and sensor subsystem includes the installation wiring and programming of the controller and sensors involved in the Siemens Display Table 3 7 shows the design specifications for the subsystem TOCOM Lab Siemens Display Controller detects when digital input is Fire pull switch that triggers alarm triggered by pull switch Controller enables light and alarm Controller rotates the damper on Actuate the sample damper command to simulate airflow When user triggers the switch system Wall switch that indicates occupancy responds to occupancy and enables fan Implement temperature humidity and All components were placed on a 26 5 x CO2 sensors a mobile unit 24 backboard on the cart Table 3 7 Design specifications The controller being used is the PXC Modular Series PXC100 PE shown in Figure 3 1
67. m introduces heated or outside air to heat or cool the space to achieve a desired steady state temperature The heating actuator comprises Abstract Page 1 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL a fan and a coil whose voltage is regulated by a PID controller through Pulse Width Modulation PWM Using the air control system both a thermal systems and control systems lab exercise was created with the aim to be applied by future students in thermodynamics and controls labs in the University of San Diego where the project has been developed Real time data collection using LabVIEW allows for the analysis of the thermal efficiency of the system with and without a reheat configuration The parameters of the control system can also be varied using LabVIEW to provide an instructive exercise in the design of control systems Furthermore the results gathered in the real system could be compared with the simulation responses obtained when running the non linear model implemented in Matlab An example is shown in Figure 1 2 Comparison real system LabVIEW simulation Matlab 30 5 Simulation 30 Matlab 29 5 29 Real system 28 5 LabVIEW Temperature C 28 27 5 100 150 Time sec Figure 1 2 Comparison between real system and simulation responses Abstract Page 2 UNIVERSIDAD PONTIFICI
68. mperature humidity sensor in the top left corner of the board Fortunately the values for that sensor can be found in the GUI 4 2 7 Guide User Interface GUI Display Temperature Observe the displayed results Pass 2 and Humidity and test with another temperature sensor on separate system verify results Easily Navigable GUI Distribute a survey to students 90 18 20 and team members receive feedback Switch to Activate Turn on switch and see if fan Pass system turns on and observe if the values on the GUI reflect this change Display Alerts Watch the values exceed the Pass Alarms set limit and observe if an alarm is activated Table 4 9 Testing Procedure and Results for GUI The display of temperature and other values are tested by observing if the system is in fact displaying values To ensure that those values are correct Part I Report P gina 65 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL other separate sensors measure the temperature and the results are compared to verify the correct values The results show that the system does in fact display the Temperature CO2 and Humidity values The alerts and alarms are tested by making the values exceed the set guidelines for too high and observing if the alarm goes off The results show that the alerts
69. mperature set is 33 degrees Celsius The team decided to do this because it Part I Report Pagina 54 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL takes close to twenty minutes for the system to reach its max temperature where as it takes less than ten minutes to reach a steady state at 33 degrees Celsius Differential Flow Pressure Rate 0 4 9 839609 0 5 11 00102 0 6 12 05101 0 7 13 01658 0 8 13 91531 Operating Point 0 9 14 75941 1 15 55779 1 1 16 31715 1 2 17 0427 1 3 17 73861 14 18 40822 1 5 19 05432 Table 4 3 Differential Pressures and Corresponding Flow Rates Throughout all of the tests including the maximum temperature tests the housing for the fan and heat coil as well as the piping stayed intact and without any type of structural failure 4 2 3 Controls The running of the real system has been accomplished effective gathering of information transmitted by the sensors transmission of control signals actuators powered by relay transformers and implementation of the final controller in LabVIEW Table 4 4 shows all the specifications with their corresponding testing procedure Part I Report Pagina 55 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Correct interfacing between Pass components temperatur
70. nalyzing efficiency The values of efficiency for some configurations are displayed in Table 4 7 27 open 43 60 27 reheat 53 50 33 open 62 45 33 reheat 43 90 Table 4 7 Efficiency of the air temperature control system Note that the efficiency decreases for the system with reheat compared to the open system at 33 SC This indicates the optimum operating point for the reheat configuration is below 33 C Time to meet these temperature set points was 7 minutes on average enabling the completion of the lab without excessive downtime Part 1 Report P gina 62 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL 4 2 6 Controller and sensors Table 4 8 shows the tests that were conducted on the system The first test conducted was to make sure that the fire strobe light flashes when the fire pull switch is triggered This was tested by first examining the program before uploading it to the controller making sure the correct variables were utilized and that the code was able to be compiled Then the fire pull switch was triggered by pulling the white lever on the sensor backboard The test was a success on the first attempt due to the correct labeling of variables and understanding of code Fire pull switch enables strobe Pulled fire alarm Pass light Room occupancy wall switch Flip wall switch on Pass enabl
71. ntial pressure gage provides students with a differential pressure reading in Inches Water Column Students following the lab instructions will use this value to calculate the flow rate in the system The process to calculate flow rate from a pressure reading is shown in the lab instructions Fan Housing 9 Inlet Temperature Thermocouple c Heating Coil Housing c Total and Static Pressure Probes c Figure 3 6 HVAC System Layout Thermocouples have been installed into the system as well thermocouples were used to test the ability of the heating coil to heat the air as specified by the user through LabVIEW Figure 3 6 also shows the location of the inlet temperature thermocouple This sensor is used to measure the temperature of the air before it passes over the heating coil Another thermocouple is placed inside of the control volume to measure the temperature of the air after it has passed over the heating coil These measurements provide feedback to the control system Part I Report P gina 19 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL 3 3 Controls demonstration The major goal of the controls subsystem is to serve as a practical tool in the design of control systems which are crucial in the majority of industrial systems The main goals that the controls subsystem will allow the user to accomplish a
72. o National Instruments and has the following features 4 gt 8analog inputs 10 volts gt analog outputs from 0 to 5 volts 12bits gt 12 digital input outputs con logic values from 0 to 5 volts gt Counter of 32 bits This device is able to carry out multiple tasks simultaneously which means that the USB 6008 can gather information and generate analog and digital outputs atthe same time This capability is indispensable to develop a control system Since the DAQ works better with software belonging to the same company National Instruments LabVIEW is the most suitable tool to use LabVIEW is a graphic programming language for the design of data acquisition systems instrumentation and controls In addition it is compatible with programs or other applications like MATLAB Thus the controls design will be implemented in MATLAB but imported and run in LabVIEW Hardware components The control systems that will be studied is a non linear SISO system single input single output which means that one variable will be controlled temperature inside the enclosed environment through one actuator Part 1 Report P gina 21 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL resistive coil In this sense the rest of components fan will be independently activated from the control loop by the DAQ The temperature sensors chosen are 4
73. oint The procedure consists on taking the output and input of the plant Figure 3 12 in the operating point and apply and iterative algorithm to get the value of the transfer function parameters when the error approaches to zero Since the plant includes an integrator it is necessary to add a close loop proportional controller to the plant so that the identification can be obtained without unestabilities In this case a proportional controller of K 0 2 has been applied successfully Files programmed in Matlab for identification are included in the Appendix Chapter 3 Part I Report P gina 29 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Finally the linearization allows to design the final controller to be implemented in the system Considerations in controller design The implementation of both analog PID controller and PWM give rise to a discrete controller which means that the period of the PWM is crucial when it comes to design the controller An unsuitable choice of the period can lead to an unstable response To make clear the limitations of the design Table 3 4 shows the ratio between the speed in open loop controller design multiplied by the plant and the period of sampling PWM 1 After designing the controller this ratio has to be checked so that it has to be in the range of small If the controller is not included or close to
74. omparison of similar systems with and without recirculation of conditioned air Part 1 Report Pagina 7 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL C Provide Exercise in Control Systems Engineerin e The control system of the enclosed environment can be changed in accordance with user input e The lab shows how variation Proportional Integral Derivative PID controller parameters will change how the system response to a desired input e The lab will be equipped to show how a non linear system can be converted to a linear system and the results will be displayed D Display Values of Sensors e The sensors on the lab provide real time measurements to the GUI The control devices provide responses to user inputs to the switches installed on the cart e The controller is programmed to run specific routines if specific inputs are detected 2 3 Physical specifications The TOCOM Lab was required to be mobile allowing for the transportation of the cart between different labs in engineering s building implying it would be able to fit through doors and on the elevator The TOCOM Lab was built aboard a cart which has a footprint of roughly 4ft by 2ft and a maximum height of 64 inches The cart is mounted on 4 swivel wheels which facilitate positioning within the labs The TOCOM Mobile Cart supports the onboard subsystems by provid
75. ompartimento y asi alcanzar la temperatura deseada r gimen permanente El actuador del sistema de control est formado por un ventilador y una resistencia el ctrica cuyo voltaje es regulado por un controlador PID a trav s de modulaci n por ancho de pulso Empleando el sistema de control construido y desarrollado se han dise ado dos gu as de laboratorio que ser n aplicadas por futuros estudiantes en los laboratorios de termodin mica y de controles de la Universidad de San Diego donde este proyecto ha sido desarrollado Gracias al dise o de una interfaz y la implementaci n de controles en LabVIEW es posible la obtenci n de datos en tiempo real y realizar un an lisis termodin mico de la eficiencia del sistema en las dos configuraciones dise adas con y sin recalentamiento En la pr ctica de controles dise ada se podr variar los par metros del controlador para ver su efecto en el sistema y comparar los resultados con el modelo no lineal que se ha implementado en Matlab Un ejemplo se muestra en la Figura 1 2 Comparison real system LabVIEW simulation Matlab Simulation Matlab w Real system LabVIEW N 9o Temperature C 9 c 100 150 Time sec Figura 1 2 Comparaci n entre la respuesta del modelo real y simulaci n Resumen P gina 2 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO E
76. omponents must be contained on the mobile cart to make it easier to use and move Finally components concerned with the Siemens Control Demonstration must be obtained from Siemens and their software Insight must be used as well Part 1 Report P gina 5 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Chapter 2 Design specifications Before going into details about contruction programming implementation this chapter has the aim to explain the specifications that the different subsystems have to fulfill Setting the specifications is really important to understand the different subsystems involved in the project meet the requirements and come up with a suitable design 2 1 Design overview As it has been mentioned before the project is basically composed by two sections whose overall design is going to be described next Air Control System The footprint of the constructed laboratory is 4 feet in length and 25 inches in width to facilitate transportation throughout the enginnering building The most important goal of this lab design is that it be able to maintain a controlled environment while at the same time being able to demonstrate the energy efficiency capable through the use of control systems The control system maintains the environment by intermittently hot air or pumping fresh air to achieve a steady state temperatu
77. ontrolled space by LabVIEW software readings using LabVIEW Ability to measure power Lab test volunteers gave 10096 of users provided to fan and heating feedback on success of capture could export the element system data from LabVIEW Ability to measure differential Lab test volunteers gave Part I Report P gina 60 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL pressure through the system and feedback on success of mass 100 of users use for mass flow rate calculation flow rate calculation correctly calculated the flow rate Lab test volunteers gave Lab exercise can be completed feedback on the length of time Average of without excessive time to reach required to complete the minutes to reach temperature set points exercise Initial fail error in equations was Lab exercise can be completed Lab test volunteers gave revealed after with only instructions provided by feedback on successful revision 100 of the lab handout completion of the exercise users could correctly calculate the efficiencies Table 4 6 Requirements Testing for Thermal Systems Lab The design and configuration of the TOCOM Mobile Lab was dependent on the successful integration of the HVAC system and air temperature control system The thermal systems lab exercise utilizes all three properly integrated subsystems allowin
78. perature T2 will be room temperature Part III Appendix Pagina 91 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL PlotO 20 1 1 7 37 34 319 7 40 54 319 4 27 2011 4 27 2011 Time Figure 7 Steady state reading in LabVIEW Measurements are displayed within the Thermal Systems tab and can be exported to Excel after the program has stopped running Before collecting data be sure to clear the current data by right clicking each graph and selecting clear chart After sufficient data has been collected stop operation of the system by clicking the stop process button To extract data right click the graph displaying the desired data select Export then Export Data to Excel Excel will automatically open with the data displayed Collect data points for each temperature set point at 28 30 and 33 C note that the room temperature affects the speed to reach the set point Part III Appendix Pagina 92 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL 4 2 Part B Investigation of reheat loop in air heating system Close the exhaust valve and remove the end cap The system geometry is now in the reheat configuration The valve configuration for the closed system is shown in Figure 8 EXHAUST O
79. r License 5 000 00 5 000 00 1 666 67 1 538 670 Trunk Interface 806 36 806 36 268 79 1 Dell Computer Monitor 1 100 00 1 100 00 366 67 Total 27 791 01 9 263 67 Table 1 1 Siemens display parts list Part II Budget Pagina 69 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL 1 Inline Electric Valve 3 Orbit 57101 Home Depot 35 97 PVC SOEL 3 Valencia Pipe 120 Home Depot 171 1 M Adapter 4 Valencia Pipe 436 010HC Home Depot 272 1 Tee SSS 2 Valencia Pipe 401 020HC Home Depot 114 ABS Bushing 2 VPC C5801 2 F Home Depot 5 50 PVC Bushing 2 Valencia Pipe 439 131HC Home Depot 192 1 x 2 Valencia Pipe 2201 Home Depot 53 34 3 x 2ft ABS 1 1202 Home Depot 7 75 ABS Coupling 2 C5801 Home Depot 5358 Turbo Styler 1 Revion 063 09 0473 Target 19 99 Bonding Adhesive 1 Oatey 30812 Home Depot 7 86 Electrical Tape 1 Tartan 1710 Home Depot 0 68 92 16 Total System Cost 1 x 4 x8 4 Rancho Cucamunga Home Depot 17 12 2 x 6 x8 2 Rancho Cucamunga Home Depot 7 28 2 x 4 x 5 8 Plywood Panel 1 Boise 1511004 Home Depot 17 47 2 x 4 x 1 8 Plywood Panel 1 Boise 103095 Home Depot 20 80 36 x 30 Acrylic Sheet 1 Optix MC 06 Home Depot 51 76 1 2 1b Screws 1 Grip Rite 158CDWS1 Home Depot 5 94 2in Steel Screws 1 Grip Rite 2CDWS5 Home Depot 5 94 Bag of 4 Caster Screws 4 Richelieu Hardware 8200 Home Depot 5392 3in Caster Wheel 2 Richelieu
80. re Part 1 Report P gina 6 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Siemens Control Demonstration To convey the basics of control systems and their associated devices the lab is be outfitted with a series of sensors for temperature humidity and 2 The lab is also equipped with a VAV box which demonstrates how the controlled environments in building systems are regulated 2 2 Functional specifications Primary functions of the project are related to the user interaction with laboratory exercises and the Siemens Control Demonstration Users must be able to activate all components via the onboard computer or switch related to the demonstration Descriptions of the projects functional specifications are explained in more detail below A Maintain Temperature e Temperature sensor reads actual temperature within a range supporting the lab exercises e A fan and heating coil add a heated volume flow rate to the enclosed environment e The virtual control system run in LabVIEW interfaces with the physical system via a DAQ Data AcQuisition device B Provide Exercise in Thermal Efficiency Analysis e The thermal systems lab provides an opportunity to analyze and compare efficiency of different thermal systems e Onboard data collection facilitating the calculation of efficiency e Variable system configuration allowing for c
81. re e Analyze and observe the main features of the response in a control system stability precision speed and overshoot e Design of controllers through frequency response techniques starting from stability speed and overshoot specifications e Observe the differences between simulation and real systems Some important tasks have to be accomplished in the design of the control system data acquisition and components choice The data acquisition consists of gathering samples of the real world analogical system to generate data that can be manipulated by a PC or another electronic system digital system The device that transforms the signal used by the computer is the DAQ data acquisition device This process can be shown in Figure 3 7 HRPC SOFTWARE emo JVA gt sdil cor T 29 COUNTER U SENSORS CATR ACOUSMON meo e EOF Tues Figure 3 7 DAQ Interface diagram Part 1 Report Pagina 20 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL The three different parts that comprise the subsystem input output components choice DAQ selection software and control design will be explained in depth DAQ selection and software The DAQ that has been chosen for this project is the DAQ NI USB 6008 which belongs t
82. re the room and duct sensor The room sensor 540 680FB shown in Figure 3 15 is a wall mountable unit with an LCD on the front of the unit to display current temperature in degrees Fahrenheit F or Celsius C The unit can measure the temperature range from 55 F to 95 F 13C and 35C and has a set point slider under a small cover in the front with the same range It uses a 10K Ohm thermistor with 0 5 accuracy similar to that of the duct sensor shown in Figure 3 16 The duct sensor is a rod with a base attached to the end of the unit The tip of the rod is placed inside a duct to measure the temperature Duct sensors are common in areas where a wall mounted sensor may be tampered with or damaged They can be placed out of sight in the return duct of a room Part I Report P gina 36 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Figure 3 16 Siemens Room Temperature Sensor Left and Duct Temperature Sensor Right An air quality sensor QPA2000 refer to Figure 3 17 is important for determining the level of CO2 in a room It determines the amount of CO2 in parts per million ppm and creates a 0 to 10 VDC linear proportional output signal The sensor has a range of 0 to 2000 ppm Outside CO2 levels generally vary between 300 and 400 ppm while room levels should not vary higher than 600 to 700 ppm Ifthe level reaches 600 ppm in a room th
83. rs fan motor and electric resistive heating coil within the HVAC loop are activated and controlled by relays thrown by the control system Operated through a computer with LabVIEW and interfaced to the HVAC loop through a data acquisition device DAQ the control system actuates the devices to control the air temperature in the enclosed environment The control system compares the measured temperature to a user specified temperature and responds by adding heated or cool air to the enclosed environment The block diagram for the HVAC Demonstration is shown below in Figure 3 1 Part I Report Pagina 10 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Computer LabVIEW Thermocouple 1 root Thermocouple 2 eating Coil HVAC System Enclosed Environment Figure 3 1 Block diagram for air control system The Siemens display is composed of a PXC Controller that is connected to a group of sensors that send their respective results back to the controller for analysis In addition to the sensors a Fire Alarm Pull Switch is connected to the controller which turns a Fire Strobe Light on when pulled All of these values along with an explanation for the system s design are placed in a GUI Part 1 Report P gina 11 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y
84. rs and GUI interface 73 A 1 Controller and sensors 73 A2 BULA pen mm ir Um EU 76 Appendix B Thermal systems lab ccccscsccssscececeeeceeeeeeeseseeeeeeeeeeeeeeeeeeeeeseeeeeeeeeees 82 AppendiE Controls dri vci da 98 EL SENS Manta asada 98 C2 99 Appendix D Plans ai 105 0 1 Cart assembly 106 D 2 HVAC installatIOn aaa 107 List of Figures Figure 3 1 Block diagram for air control system 1iError Marcador no definido Figure 3 2 Block diagram for Siemens display 12 Figure 3 3 Overall system layout diagram rerit r rrr erar noon a 13 Figure 3 4 Picture of actual display eter inr tren ti rud ii 13 Figure 3 5 Valve and end cap locations eese eene eene eene 17 Figure 3 6 HVAC system la yo pct duda d PRA quA 19 Figure 3 7 DAQ interface 2 212 00000111 000000050 20 Figures S 22 Figure 3 9 PCB board m 23 Figure 3 10 connectlons cce nre ES EX HEX GH RS is agas gai GAA 24 Figure 3 11 Flowchart of the overall process 2100 0 0 0 0 00004002 008000000 5 9
85. rsidad Pontificia Comillas 2 F Luis Pagola Regulaci n Autom tica Universidad Pontificia Comillas 3 Frank P Incropera David P De Witt Fundamentos de transferencia de calor 4 National Instruments www ni com 5 Isaac P rez Moreno Manual de pr cticas de control avanzado utilizando la tarjeta de adquisici n de datos NI USB 6008 6 Siemens APOGEE Actuating Terminal Equipment Controller owners manual 7 Siemens Introducing the Zone Control Unit Part 1 Report Pagina 67 TIWN 9 ts Sa UNIVERSIDAD PONTIFICIA COMILLAS PART II BUDGET ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA P gina 68 Part II Budget UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL 1 Budget This section includes a detailed budget that has been required to succesfully develop the Project Labor budget Considering an average engineer s remuneration of 0 our and 300 hours of total work the final cost is Total cost 300 hour 150005 Hardware Tables 1 1 and 1 2 show a detailed part lists of both Siemens and HCAV components with their corresponding prices Product Number Part Description Retail Price Total Siemens Price 1 PXC100 PE A PXC Modular w FLN 8 TX I O 7 097 22 7 097
86. s the steady state temperature within the system must be configured before beginning the experiment Part III Appendix Pagina 90 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Under the PID tab enter the following values in their respective fields Kp 10 Ki 0 1 Kd 0 01 Under the PWM tab enter the values in their respective fields Precision 25 Rate Time 5 Amplitude 5 In LabVIEW under the PID tab change the temperature set point desired_temp to 28 Enable the control system by clicking the left pointing arrow icon in the top left corner of the LabVIEW window Allow the system to reach steady state temperature this will be evident by a flat trend in the temperature display under Thermal Systems tab Here the control system will maintain the temperature in the controlled space by intermittently actuating the heating coil The fan should always be running While the enclosed space is being heated record the pressure reading from the differential pressure gauge within the controlled space visible through the controlled space window Once the temperature set point has been reached and the system is at steady state seen in Figure 7 use LabVIEW to collect temperature readings from both the controlled space T1 the air inlet T2 and power supplied to the fan and heating coil note that for part A the inlet tem
87. same conditions do they match Why 2 Programs Program prep_adjust m 55 Program to prepare data before algorithm application ts 1 plot presion 2 Clicking two times the time range we want is defined aux1 aux2 ginput 2 auxl ceil auxl the time range is shifted to zero time presion auxl1 1 aux1 2 1 presion auxl 1 1 Part III Appendix Pagina 99 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL tfin time end 5 end time of the simulation We pick out the interval of time desired presionf presion 1 1 auxl1 2 2 combustiblef combustible 1 1 1 2 2 5 Initial levels presion 0 mean presion auxl 1 2 combustible 0 combustible auxl 1 2 5 Input and output set ent combustiblef combustible 0 sal presionf presion 0 Program adjust m ALGORITH SYSTEM ADJUST ALGORITH BASED ON MINMUM QUADRATIC ERROR clear all clear theta thaux dgn J format compact format short e 55555555 PARAMETERS AND INITIAL VALUES 9 th 2 7192e 001 1 0516e 002 SINITIAL VALUES theta th Np length theta NUMBER PARAMETERS 555555555555 PARAMETERS OF THE ALGORITHM tfin length time 1 Tsamp ts Nd tfin Tsamp toll 1 tol2 1 V 1 Vaux 0 01 dgn ones 1 Np ni
88. software Temperature data will be collected via thermocouple sensors placed throughout the system and displayed through Part III Appendix P gina 84 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL LabVIEW A detailed diagram of the airflow and devices within the system can be seen in Figure 2 1 and T2 indicate the placement of the controlled space temperature and inlet temperature respectively HEATING FAN ELEMENT gt e Controlled Space EXHAUST Exhaust valve Figure 2 HVAC circuit diagram The valves can be set to two positions which change the system geometry from 1 open without reheat to 2 open with reheat By closing the reheat valve the system changes from configuration 1 to 2 The reheat system valve configuration is shown in Figure 3 Part Appendix P gina 85 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL ENDCAP ON Figure 3 Open valve configuration Pressure is measured via a differential pressure gauge which compares the stagnation pressure and dynamic pressure of air moving through the inlet to the controlled space see Figure 4 Part Appendix P gina 86 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN
89. t one could see an easy way to go back through the pages Given this information it was decided that two buttons should be placed at the top right and left of each screen that gives the user the option to go back to the last page shown by a green arrow in the top left corner and return back to the homepage shown by a House in the top right corner The images for each navigational button are shown below in Figure 3 20 Figure 3 20 Back and Home buttons To meet the design goal of displaying the values we first created point addresses These point addresses assign each sensor a point that is called in the GUI to display the reading from that sensor When a user clicks on a sensor the readings from that sensor are sent to the point created and subsequently displayed on the page The points created are seen in Figure 2 21 Part 1 Report Pagina 42 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL Point Details Object Selector Look in x El DK TCM ALM 01 FIRE TCM SNR 01 C02 TCM SNR 02 TEMP TCM SNR O3 HMDY TCM SWT 01 FIRE O TCM SWT 02 0CPY Cancel ESATOCOM ATEC Hann GQ TOCOM amp TOCOM ATEC2 1 TOCOM_PPCL Options 4 n Find Objects that match these criteria Nane y Find now Type Port Show Pane lt All gt subpoints 10 Object s R
90. t 4 thermocouples have been used may not be enough to calculate an accurate average temperature Although of these inconvinients the model is accurate enough to proceed with the development of the labs Part 1 Report Pagina 59 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL 4 2 5 Thermal systems lab Testing of the Thermal Systems Lab was focused on ensuring a smooth completion of the laboratory exercise Points of interest in testing included the ease of operation of the TOCOM mobile unit ability to gather relevant data and clear instructions for calculation of efficiency Volunteer engineering students were asked to perform the lab by following the directions provided by the lab handout They were then asked to complete a survey form tailored to gauge the success of the lab in each of the testing areas The form is included in the Appendix Chapter 2 The testable areas are illustrated in Table 4 6 A Lab test volunteers followed the students to compare power lab procedure and gave feedback After 100 revision Thermal systems lab enables of users could complete the savings due to recycling loop lab full ab successfully 100 of users Acquisition of temperature could take Temperature readings before and measurements of air at source temperature after addition of heat and in c
91. t be supported physically and electronically Functional Requirements TOCOM s mobile cart must fulfill the following requirements GUI allows user to interface with control system devices Confined space must be able to maintain a prescribed temperature at steady state Construction and implementation costs less than projected budget Readings for temperature CO2 and humidity displayed for public access Entire control system can be displayed to users Part 1 Report P gina 4 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL The GUI LabVIEW and both the thermal and control systems lab exercises need to be stored on the computer that can be used by a person standing up or seated on an elevated lab chair 1 2 2 Assumptions The design has been constructed based on the following assumptions Mobile Lab will be used within in the engineering labs e Siemens will provide the team with the suitable components in accordance with a budget e The lab cart will have access to a power supply whenever it is to be used 1 2 3 Constraints On the one hand laboratory must conform to safety protocols for electrical and mechanical safety so users will be protected from moving parts sources of heat and electrically isolated from dangerous components such as wires or transformers On the other hand laboratory and c
92. t e 1 e TOM US io DESIGNT DESIGNZ 2 DESIGNS 2 DUCTTEMPERATURE IRE FIRST lt HUMIDITY TEMPERA 2 TEMPERATURESENS i WELCOME TCM SNR The readings are listed here units Parts Million BB Graphics File View Insert Dynamic Tools Window Help ax Ojajuj je lt le slaa Assel EE Ps eje ele H The Beginning _ 3 02 31 DESIGNT 1 DESIGNZ Product PXC Controller DESIGNS Provided by Siemens eec Der Retail Cost 7 097 22 HUMIDITY E MUMIDITY TEMPERA TEMPERATURESENS WELCOME The controller is Brains of system all coding that tells the system when to sound an alarm is stored here In addition all sensor readings are analyzed in the controller and then the proper actions are taken based on the readings received The parts labeled a g represent the different sections of the controller that each have different properties Block A Power Supply for all terminal blocks Block B 16 Digital inputs Block C 6 Digital outputs with manual overide Block D Same as Block C Block E 8 Analog Inputs or Outputs Block F and G Same as Block E Product Fire Alarm Pull Product Fire Strobe Light Switch Provided by Siemens Provcided by Siemens Retail Cost 69 12 Retail Cost 78 99 The Fire Alarm Pull Switch is wired into the system through t
93. tage free contacts with a maximum rated voltage of up to 250 VAC at 4 amperes A The override button allows for each point to be controlled manually on the Terminal Block itself It has green light emitting diodes Part I Report Pagina 35 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL LEDs for each point on the module The fourth module is the same as the third The last three modules are universal blocks TXM1 8U ML TXM1 8X ML shown in Figure 3 15 blocks E F G Each of the eight points of the individual blocks can be configured as a DI analog input AI or analog output AO to meet specific application needs This block also features a liquid crystal display LCD that displays information for each I O point on the module configured signal type input or output symbolic display of process value a bar indicating how much voltage or current is being measured and notification of faulty operation short circuit or sensor open circuit The blocks also have outputs for 24 VAC and 24 VDC to power the sensors and components The controller and all the expansion Terminal Blocks provide more than enough points for all the sensors and components that will be connected There will be two different types of temperature sensors a CO2 sensor and a humidity temperature sensor The two types of temperature sensors that Siemens produces a
94. ter 0 5 5 5 5 5555555555 55 5 ALGORITHM Part III Appendix Pagina 100 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL while 100 V Vaux Vaux gt toll 100 max abs dgn theta gt to12 amp niter lt 10 niter niter 1 ITERATIONS INCREASED parameters updating th theta Sh0 theta 2 sistem simulation sim sistema tfin 1 2 sym sal sall sal2 ym sal error ys ym target function V sqrt sum error 2 Nd building of jacobian matrix for i 1 Np thaux theta h 001 abs theta i 5 Incremento para las derivadas if abs theta i lt 10 sqrt eps h 01 sqrt eps end thaux theta 1 th parameters updating th thaux shOsthaux 2 sim sistema tfin Syaux y y1 y2 1 yaux y sym sal sall sal2 ym sal error yaux ym J 1 yaux ys h end Graphic representation de ys ym and error ys ym erf Part III Appendix P gina 101 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL stairs ym ys error grid disp PAUSE pause disp VALE dgn JN ym ys 5 mu 2 Vaux V 10 stb 1 while Vaux gt V stb
95. the range it has to be redesigned or the PWM period changed Table 3 4 Discrete periods In this case the period utilized should not be a problem since the constant time of the process temperature dynamics is big enough to use a big range of periods A range from 1sec to 10 sec is recommended Finally a PID controller will be provided with the aim to be a reference for future comparisons between controllers 2 PWM parameters are also included e Kp 10 0 1 e Kd 0 01 25 e PWM period 5 Part 1 Report Pagina 30 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL e Amplitude 5 LabVIEW interface As mentioned before the LabVIEW interface should include the controller in charge of activating the actuator of the controlled system coil and the fan The standard controller implemented is a PID which will be used in conjunction with Pulse Width Modulation PWM to activate the relay of the coil so the analog output signal of the controller is converted into a digital signal 5 Users will be able to configurate PID and PWM parameters LabVIEW interface is shown in Figure 3 13 LabVIEW schematic including controller and PWM is shown in Figure 3 14 STOP PROCESS STOP PID PWM Box temperature Thermal Systems PWM Output E Precision y
96. tilation After much programming it became clear that a single multi conditional statement was all that was needed The fourth test was to make sure that the ATEC was correctly installed onto the VAV box and wired to the FLN network to communicate with the main PXC controller The ATEC has a built in actuator that rotates the damper in the VAV box to limit the airflow The first test on the device was to make sure the ATEC was able to rotate the damper when given a command from a computer directly plugged into it After that succeeded the device was connected to the PXC controller through the FLN network and a command was sent from the desktop computer running Insight instructing the device to rotate the damper 50 about a 45 angle This to some surprise worked without hesitation proving the successful installation and networking of the ATEC The last test conducted on the system was to make sure users of all heights could easily see all the sensors on the backboard Five individuals were selected based on a variety of heights ranging from 5 foot 3 inches to 6 foot 3 inches and asked to examine the sensor backboard Four out of the five Part I Report Pagina 64 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA T CNICA SUPERIOR DE INGENIER A ICAI INGENIERO EN AUTOM TICA Y ELECTR NICA INDUSTRIAL people could see all the components on the backboard with ease One person had a slight difficulty reading the display of the te
97. troller Finally the results obtained will be exported to LabVIEW to run the real system 2 Lab work e A Plant identification 1 Run initial parameters m and run linearization mdl This file gathers the input and output at the operating point 2 Run prep_adjust m and select clicking twice the step that is going to be identified 3 Run adjust m and get the transfer function Part Appendix P gina 98 UNIVERSIDAD PONTIFICIA COMILLAS ESCUELA TECNICA SUPERIOR DE INGENIERIA ICAI INGENIERO EN AUTOMATICA Y ELECTRONICA INDUSTRIAL Design of PID controller 1 Open design_PID m and introduce the transfer function obtained which is named as p 2 Choose appropriate parameters for the PID filter factor margin phase differential factor integrative factor Run the file and get the transfer function and parameters for the PID This file is based on the Newton Raphson algorithm and provides the optimum parameters 3 Open PID_test that includes the whole control system in Simulink Change the parameters proportional derivative and integral and assess the effects they produce in the response 4 Get the parameters for a time response with 20 overshoot 50 2 of margin phase and the quickest rising time C Running the real system Using one of the parameters obtained in Step B export them to the LabVIEW interface and run the system Compare the outcomes with the Matlab simulation under the

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