NOVAR PLC 2003, 14 Oct 2003

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…an overview to HVAC Controls & BMS

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 NOVAR PLC 2003, 14 Oct 2003
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Objectives

To gain familiarity with:

 Basics of Controls
 Controls Loops
 Implementing Control Loops in HVAC
 Valve Fundamentals
 About BMS

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Why have Controls and BMS ?

Comfort Safety Economy

• Too hot/cold • of People • Save money

• Too dry/humid • of equipment • Use just the right amount of
energy (electric power, gas
• Too polluted
etc.)
• “Sick Occupancy”
• Increase equipment life by
• Health and Safety using it efficiently
• 21 Deg C/ 50% RH • Protect equipment and
products (avoids wastage -
•24 Deg C/ 50% RH
paintings in a gallery,
• Enough Fresh Air drug/chemical stores)
• Clean Air • People’s productivity
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Why have Controls and BMS ?

Comfort
People lose heat (feel cold) - amount they lose depends on temperature
around them - cooler it is, more heat they will lose through their skin
OR they “generate” heat (feel warm/hot - WORK TOO HARD!) - need to
cool them down by reducing air temperature around them
People feel “muggy” - the air around them has too much moisture
People feel “dry” - not enough moisture in the air around them
Buildings (where people live and work) also lose or gain heat (through walls,
Windows, floors, roofs, heat generating equipment e.g. VDUs, and computer
equipment)
• Need to ADD/REMOVE heat and/or moisture
• Need to clean (filter air) and supply adequate fresh air

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Why have Controls and BMS ?

Safety
Can’t have heaters (boilers) or coolers running “wild” - they might blow
up or freeze up!
If too hot or cold for long period of time - affects their health
If starved of clean fresh air - then !!!
Sometimes you have special needs for process (making capsules,
fiber, etc)
Hospitals may have special needs for patients / medicines / labs

• Need to provide protection against equipment running “wild” / out of control

• Need to make sure people are safe at all times

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Why have Controls and BMS ?

Economy
Electric power or fuel (gas, coal, oil) is expensive and limited (?)- need to use
efficiently
Environmental issues (Clean atmosphere for the occupants)
Need to ensure maximum return on investment - prolong equipment life and get
the best out of it
Increase productivity of people increased profits for offices, hotels, etc.
Ensure that products you are making/ supplying (e.g. supermarket) do not
deteriorate because of bad “environment”

• Use energy efficiently - use plant efficiently - make people comfortable

(they will produce more???)

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Air-conditioning in large buildings

Basic issues are same - Comfort, Safety, Economy,
but….
 Larger areas to be heated or cooled therefore bigger
equipment
(e.g. Chillers, pumps, valves)
 Different types heating/cooling equipment are used.
 Operational needs are different e.g.
– different areas of the buildings occupied at different times
– different areas have differing heating/ cooling
requirements
– Central monitoring point for Building Energy
Management System

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Managing large building?

 Control and Monitor
– Room (Air) temperature, humidity, pressure, ventilation
– Boilers (Hot water services)
– Chillers (chilled/cold water services)
– Pumps
– Fans
– Lights
– Flow
 What types of buildings and facilities do you think can use
controls and BMS?
– Any building

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BASIC Control Theory

 Scenario: You are in a room and it is summer. There is a air-conditioner
in the room which can be switched ON or OFF via a switch on the wall.
There is also a thermometer in the room. Your task is to maintain 23
deg C in the room. How would you do this?
Answer:

23 deg C

Problems:

Power
Switch

All well & good but are you going to stand

there all day controlling the A/C ON or
OFF?

….surely we can AUTOMATE! How?

A/C
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BASIC Control Theory

 What were you actually doing?
– READING the temperature measured by the thermometer
– EVALUATING (comparing the required temperature and the actual
temperature)
– DECIDING whether to turn the A/C ON or OFF
– OPERATING (actuating the switch accordingly)

23 deg C Sensor

Controller
(programmed
for 23 deg C)
Switch Power
Automatic Switch Power
(relay)

A/C A/CHoneywell Proprietary

 NOVAR PLC 2003, 14 Oct 2003
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BASIC Control Theory

 AUTOMATING the controls solution

 Controls/BMS Industry would represent the solution as follows:

CONTROLLER

Sensor Inputs
Sensor

Relay Controller
Logic/ Strategy (programmed
Output for 23 deg C)
COMPARATOR
Automatic Switch Power
(relay)

23 deg C

A/C
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BASIC Control Theory

 CHANGED Scenario: You are in a room and it is summer. There is a
A/C in the room which can be controlled via a dial on the wall such that
the amount of heat from the cooling can be adjusted from nothing (0%)
to full (100%). There is also a thermometer in the room. Your task is to
maintain 23 deg C in the room. How would you do this?
Answer:

23 deg C

Dial Power

All well & good but are you going to stand

there all day turning the dial? Moreover
How do you know how much to turn!

….surely we can AUTOMATE! How?

A/C
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BASIC Control Theory

 What were you actually doing? - As before except….
– READING the temperature measured by the thermometer
– EVALUATING (comparing the required temperature and the actual
temperature)
– DECIDING whether to turn the A/C power UP or DOWN (say 1/4 turn of the
dial for every deg C that the temperature is away from 23 deg C)
– OPERATING (actuating/turning the dial accordingly)

23 deg C Sensor

Controller
(programmed
for 23 deg C)
Dial Power
Power Regulator Power

A/C A/CHoneywell Proprietary

 NOVAR PLC 2003, 14 Oct 2003
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BASIC Control Theory

 AUTOMATING the controls solution

CONTROLLER

Sensor
Power
Regulator Controller
(programmed
Sensor Driver for 23 deg C)

Power Regulator Power

21 deg C

A/C
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Pneumatic Controls
 Uses compressed air to operate Valves/Damper Actuators, Relays,
Thermostats, etc.
 Suitable where explosion hazards exists
 If good quality and material installation is proper, then Pneumatic
controls are very reliable.
 Mechanical knowledge is required at every level.
 Still used in Industrial applications, obsolete in HVAC

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Electric Controls
 Uses line or low voltage
 Uses a combination of electrical and mechanical means ( for e.g. bi-
metallic strip) for operating the circuit
 Thermostats are very popular Electric Controls

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Electronic Controls
 Uses low voltage and solid state components
 Control signals from inputs sensors are amplified
 Electronic controller is a combination of power supply, signal
amplification circuits, process/comparing circuits and output relays
 Adjustments to the sequence can be done via potentiometers, switches

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DDC Controls
 Direct Digital Controls
 Microprocessor based controls
 Perform software algorithms and complex sequences
 Uses A/D and D/A converters
 Controllers can be stand-alone or networked together

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 NOVAR PLC 2003, 14 Oct 2003
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A Basic Control Loop

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Types of Control Loop

 Open Loop Control System
– With open loop control there is no feedback.

– No information is sent back from the

process or system to indicate that all is well
or further corrective action is required.

Controller Controller

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Control Loops
 Closed Loop Control System
– closed loop control does employ feedback.

– Information is sent back from the process

or system.

Controller

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DDC Controls - The Main Players!

 The Inputs
 The Controller
 The Outputs
 The Network
 The Supervisor

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The Inputs (Analog)

 Measuring Devices (Continuous)

 Measure physical things/conditions
and convert to electrical signal
 What can we measure?
–Temperature (resistance ; Kohms)
–Humidity (voltage ; 0-10VDC)
–Pressure (current ; 4-20 mA)
–Light level
–Flow

Read Inputs –Energy

e.g. room temperature

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The Outputs (Analog)

 Speed Control (VFD)

 Modulating Dampers
 Modulate a valve
– to regulate flow of water in a pipe
 Regulate 0 to 100%

Control Outputs
e.g. AHU valve / VAV dampers

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The Inputs (Digital)

 Volt Free Contacts

 Dry Contacts
 Potential Free
Contacts
 Limit Switch
 Pressure Switch
 Normally Open
 Normally Closed

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The Outputs (Digital)

 Control Relays, Starters, Lights

 Dampers
 open/close a valve
– to regulate flow of water in a pipe
 turn things ON and OFF

Control Outputs
e.g. AHU valve / Isolation Dampers

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The Controller

 Micro-processor based
 Contains a program (“logic”)
 Reads Inputs  Controls Outputs
 Makes decisions
 The controller controls the system!

Make
Decisions
is it hot or cold?
Read Inputs Turn On and Off the cooling Control Outputs
/ heating as needed
Room Temperature Control valve / damper / Heater

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TYPES OF CONTROL
On/Off Thermostat

•2-Position Control (On/Off)

•simple 2-position +
•timed 2-position
thermometer + switch

ON

•Floating Control OFF

Modulating Thermostat

•Modulating Control
•proportional +
•proportional + integral (P+I)
•proportional + integral + derivative (P+I+D) thermometer + dimmer switch
100 %

0%

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 NOVAR PLC 2003, 14 Oct 2003
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Example: Two Position Control

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Floating Control

Valve Position
100 %

0%

Air Temperature

Upper limit

Deadzone

Lower Limit

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P + I Control

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P + I Control

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…about HVAC

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Wet & Dry Systems?

 People working in the industry refer to Wet and Dry Systems
in a building
Wet Systems: Dry Systems:
 Any systems to do with water  Any systems to do with Air e.g.
e.g. – Air Heaters (Fan heaters)
– Boilers (heat water) – Fans (makes air flow in
– Chillers (cool Water) ducts)
– Pumps (makes water flow in – Filters (clean air)
pipes) – Dampers (regulates amount
– Valves (regulates amount of of Air flow through the
water flow through heating or ducts)
cooling “radiators” or coils – Air handling units (heats,
cools, filters air - ALL IN
ONE)
Need to CONTROL and/or MONITOR both Systems
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Introduce HVAC?

Heating Ventilating Air Conditioning

Increase or ALL IN ONE - HANDLES ALL
Supply right
Decrease the
amount of
water or Air Heat Air
Clean fresh air
Temperature Cool Air
Clean Air Air
Boilers Fans Add Moisture
Handling
Radiators Air Ducts(?) Unit
Pumps Dampers(?) Remove Moisture
(AHU)
Move air
Recover wasted Heat
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...commonly speaking

 Heater battery/coil………..  Electric Heater

 Chiller…………………….  Fridge
 Fresh air damper………….  Open window
 Calorifier…………………  Hot water tank
 Valve and actuator………..  Regulator
 Filter………………………  Vacuum cleaner filter

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HVAC Systems

 Major HVAC systems are :

– Chillers, pumps
– AHU - Air handling units
– Dampers, Coils and Valves
– Fans
– Distribution ducts and terminal
boxes
– Pumps and Plumbing
– Control devices and control loops
– Unitary equipment: fan coils, VAV
boxes, etc.
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What are Air Handling Units (AHU) ?

 Function: Condition the air flow.

– Heat the air flow
– Cool the air flow
– Dehumidify the air flow
– Humidify the air flow
– Clean the air flow
– Distribute the conditioned air into the
building space.

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Types of Air Distribution

 Constant Volume, Variable Temperature (CV)
» Constant volume of air Delivered to all room areas
regardless of individual room differences .

 VAV -Variable Air Volume:

» Variable volume of air is supplied by AHU at a constant
temperature , individual zone temperature is controlled by VAV
boxes

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AHU - Components & Terminology

EA RA Return From
Space

OA

Filter DA
Cooling Coil
Heating

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Air Handler Components

 The fan section with

access door open.

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Air Handler Components

 The coil section.

Note:
There may be a wide
variety of actual configurations

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Air Handler Components

 The filter section.

Notice the cross stacking of the
filters to increase surface
area.

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AHU components
 The temperature sensors provide “feedback” for air handler control and operation. Notice
also the air filter monitor, the fan’s air flow monitor, and smoke detectors. These also
provide feedback for control.

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Basic Mixed Air Control

 Specification
– Control System will
energize when fan is on
– MA controller will modulate
dampers to maintain mixed Note:for large fan systems care must
air position
be taken to insure ample air is supplied
– Manual positioning
to fan!
switch/setting determines
Both OA and RA dampers should not
minimum OA damper
position be closed during fan operation.

– OA, EA dampers close and

RA damper opens when fan
is shut off

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Typical AHU Damper Sequence

 Mixed Air Dampers:

 Mixes OA and RA to maintain
a mixed air setpoint via direct
acting controller.
 Modulates 0% to 100%.
 Provides ventilation for IAQ.
 Provides free cooling.
 Provides proper temperature
for H/C coil operation.
 OA and EA dampers close via
relay with fan off.
 RA damper opens via relay
with fan off.

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Typical AHU Damper Sequence

 Example of
operation:
– Setpoint = 55 deg.
– MAT = 55 deg.
 Proportional
Controller output =
50%
 Fan = On
 Dampers:
– OA = 50%
– RA = 50%
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Typical AHU Damper Sequence

 Example of operation
on temperature rise:
– Setpoint = 55 deg.
– MAT = 57.5 deg.
 Controller output = 75%
 Fan = On
 Dampers:
– OA = 75%
– RA = 25%
 More outdoor air!

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Typical AHU Damper Sequence

 Example of
operation on
temperature fall:
– Setpoint = 55 deg.
– MAT = 50 deg.
– Controller output = 0%
– Fan = On
 Dampers:
– OA = 0%
– RA = 100%
 No outdoor air; no fresh
air in the building!

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Mixed Air Dampers with a Minimum Position Setting

 Maintains a “minimum”
outdoor damper position
via a minimum adjustment
device when building is
occupied. (fan on)
 Meets IAQ code
requirements.

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Cooling Process

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Cooling Process

 Typical discharge air control of

a chilled water cooling coil.
 BTU’s are absorbed by the
chilled water as air flows
through the coil.

 Dehumidification is also
provided by the cooling coil. As
the air temperature is reduced
to below the dew point
(saturation point) water
condenses out of the air stream.
In this case, a reheat coil may
be required to bring the air back
up to an acceptable discharge
temperature.

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Humidification Process

The humidification
component of an air
handler is accomplished
via a steam spray or a
water spray manifold.

Moisture is added to the

building space to
maintain an acceptable
relative humidity level.

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Fan Coil Units

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Typical FCU Types

Horizontal Vertical Cabinet
FCU Stack FCU FCU

Remote
Thermostat
Built in
Thermostat Built-in
Thermostat

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Variable Air Volume Boxes

VAV Boxes

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Variable Air Volume Boxes

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Selection

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Valve Fundamentals

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Diverting & Mixing Valves

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