ECS Computer

Controls
 I. FRICK ECS Control System

The Frick ECS Engineered Control System is custom designed, specifically for its application. From
the low side to the high side, the controller optimizes the operation of your refrigeration system to suit the
current load. Energy savings are realized through compressor sequencing, evaporator fan and defrost con-
trol, and condenser pump and fan control. Load shifting techniques may be programmed to take advantage
of low evening power rates, storing the refrigeration effect to reduce the daytime load. Alternately, demand
limiting techniques can be used to set an upper limit on the power load during times of peak power rates.
The ECS control system is based upon a user friendly Windows® operating system and incorporates
Wonderware color graphics to display an accurate representation of the current plant operating conditions.
The Windows operating system allows multiple applications to run simultaneously so that the operator
may continue to monitor the system while compiling a report. An important benefit of the ECS Control
System is that the complete refrigeration system may be reviewed at a glance.

Figure 1: Refrigeration system equipment and operating conditions are graphically displayed.

Operators can observe how changes in equipment setpoint values affect the rest of the plant. The
control system receives input from pressure and temperature sensors, microprocessors, ammonia detec-
tors, and other sensing devices. The controller displays this input information on the supervisory computer
with tailor-made graphics. The information is used by the controller (see Section II) to adjust the equip-
ment operation to achieve design temperatures and pressures while minimizing energy usage. Adjustable
setpoints and setback schedules allow operators to vary the design conditions to suit specific load require-
ments and scheduled process changes. Operators can fine tune the operating setpoints to achieve the most
efficient and effective refrigeration system.
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 In addition to reducing operating costs, the Frick ECS control system provides many other benefits to
the owner. A Frick ECS system enhances plant performance by monitoring and controlling plant equip-
ment to maintain operating levels at or near the design conditions. When the system operates according to
design, many inefficiencies are eliminated. The ECS system also maintains high product quality by holding
room temperatures at the design temperature with minimal variance. By maintaining room temperatures,
the ECS system can ensure a more uniform product cooling/freezing. Considering the additional benefits
with the power savings, the Frick ECS control system is an essential cost saving tool for all industrial
refrigeration systems.

Figure 2: The Frick ECS system is designed with a central controller and a supervisory PC.

II. Control System Structure

TheUL®, cUL® approved control system is designed with a Mistic® industrial controller or Allen-
Bradley PLC which accumulates and processes all of the necessary control information. The central con-
troller is connected to a supervisory PC which operators use to monitor the system and change design
setpoints as required. Frick uses Compaq PC's which come with CD ROM, keyboard, SVGA color moni-
tor, and a color printer. The information exchange between the controller and the PC takes place through
network cable. The PC is equipped with a modem to allow communication between outside users and the
controller through the supervisory PC and the network connection.
The master controller is housed in a NEMA 12 weatherproof panel which is cUL® approved. The
control panel contains the industrial controller which is designed for easy expansion by adding additional
digital and analog I/O. Additional controllers can also be networked together to provide unlimited expan-
sion.
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 The Mistic® controller provides memory expansion of up to 1 megabyte of RAM. The Mistic controller
is a 32 bit 68020 computer with full floating point math capability. The large I/O and memory expansion
capability allow for easy upgrades without additional controllers that require costly reprogramming of new as
well as existing controllers. Each output is provided with a hand-off-auto selector switch for manual control
and contains a replaceable fuse. The condenser fan and pump outputs are also tied to a mechanical stepping
switch or pressure switch to provide mechanical automatic control in the event of a controller failure. The
master control panel is immune to RF interference and has a built-in conditioner to protect against AC line
noise. Integrated circuit temperature sensors (ICTD)(same as compressor sensors) are used for temperature
inputs and pressure inputs are 1-5 volt pressure transducers utilizing silicon strain gauge devices.
The controller communicates with compressor microprocessors via the RS-422 port. The micro screen
can be fully transferred (see Figure 4) so that the operator sees exactly what someone standing in front of
the machine would see. The controller can start, stop, load and unload through the RS-422 connection. The
operator can change the design setpoints at the
supervisory PC, through the controller and across
the RS-422 connection.
The room temperatures are monitored by the
controller. The controller can start, stop, or cycle
fans on the evaporators as necessary. The defrost
schedule is programmed into the controller (See
Figure 5). It can initiate defrosts based upon time,
liquid solenoid “on” time, or through frost sensor
inputs to provide the most effective defrost sched-
ule. The ECS system has the advantage of limit-
ing the number of evaporator control groups that
can defrost at one time.
Figure 4: Compressor Micro screen can be
viewed remotely.

Figure 5: Operators define air unit defrost cycle setpoints to suit refrigeration requirements.
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 Figure 6: Air unit condition of operation is shown graphically.

The controller will determine when a defrost is required and initiate defrost. If another control group
in the room is in defrost, the controller will not initiate defrost until that defrost cycle has been completed.
As shown in Figure 6, air unit #9 is currently in defrost. Air units #7 & #8 are locked out of defrost. If either
one needed to be defrosted, the defrost would be delayed until air unit #9 completed its defrost.
The controller also receives input from the discharge pressure transducer so that it can modulate the
system head pressure. It provides capacity control by sequencing fans and pumps to maintain optimal head
pressure while ensuring adequate feed pressure for low side requirements. Fan and pump sequencing is
designed to keep the head pressure within specified boundaries. When the head pressure rises or falls, the
ECS system will turn on or off additional fans/pumps in sequence. The operator selects, through the super-
visory computer, the fan/pump sequence of operation.
The vessels and ancillary equipment can be monitored and/or controlled through input and output
ports on the controller. Vessel liquid levels can be shown visually to the accuracy of the sensor (see Figure
8). If a multi-level sensor monitors a range of levels, then the PC will show the liquid level corresponding
to the sensor input. Liquid refrigerant pumps can be monitored and controlled. The controller can also
receive an input to display the status of the liquid makeup device.

Figure 7: Condenser status is displayed. Figure 8: Vessel level and status are displayed.
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 III. ENERGY REDUCTIONS IN A COLD STORAGE WAREHOUSE

A typical cold storage warehouse application can be used to exemplify the energy savings which can
be realized with the Frick ECS control system. The system provides energy savings by cycling the evapo-
rators off when the room temperature is satisfied, minimizing the defrost cycles, operating at minimum
feasible head pressure, and trimming compressors to maximize their efficiency.
Historical data on typical cold storage installations of the Frick ECS control system show that evapo-
rators can be cycled off as much as 60% of the time. Conservatively, a 40% off time can be realized on most
systems. The savings due to fan off time include the heat added to the room, the energy to compress the
additional refrigerant, and finally the energy to reject the heat at the condenser. The illustration below
describes the evaporator fan motor heat rejection. In this example, there are numerous evaporators whose
sum total motor horsepower is 200 hp. This correlates to 42.4 TR of heat which must be passed through the
compressor and condenser to the ambient heat sink. To compute the power savings, it is conservatively
assumed that the fans are cycled off 40% of the time, power cost is $0.06 per KWH, and the motor effi-
ciency is 82% nominal for all fan motors and 93.5% nominal for compressor motors.

Figure 9: Sample refrigeration system with 42.44 TR low side fan motor load.

The computed power savings for the facility in a year with 95°F condensing is as follows:
Total HP = 200 + 105.3 + 5.75 = 311 HP
Power/hr = (200/0.82 + 105.3/0.935 + 5.75/0.82) * 0.7457 = 271 KW/Hr
Power/yr = 271 KW/Hr * 8760 Hr/Yr * 0.40 (off-time)
= 949,584 KW/Hr/Yr
Saving/yr = 949,584 KW/Hr/Yr * $0.06/KW/Hr
= $ 56,975./Yr

The control system ensures that the compressors operate at their optimal level. Screw compressors
operate most efficiently when fully loaded. When multiple machines are being used, maintaining one at
100% capacity is often the most efficient way to meet the load requirements. The ECS control system will
unload only one machine at a time in order to maintain the best overall efficiency. The control system
maintains the most efficient mode of operation through a varying load. When the load drops to a point
where one machine is adequate, the control system will first unload the lead machine. This is to prevent
short on-cycle of the lag compressor. Continual starting and stopping of the lag compressor is prevented
when the load is just above 100% of a single machine’s capacity.

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 Figure 10: Annual power costs for various power rates.

IV. ECS OPEN ARCHITECTURE

Figure 11: Compressor operating status is graphically displayed.

The Frick ECS Control System is designed with an open architecture system. Each component within
the system is available through commonly used distribution channels. The controller, I/O’s, and any com-
ponent used in the controller may be upgraded, replaced, or modified through Frick or any other vendor.
Frick designs the ECS system to give the user total flexibility over sourcing decisions. Even the Wonderware
color graphics software is available through other distribution channels. An owner may opt to purchase the
software and modify, update, or further customize the control system graphics. The flexibility of the open
architecture system is a distinct advantage of the Frick ECS system.

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 Figure 12: Pertinent system data is logged and can be plotted over time for trend analysis.

V. Data Trending Helps Diagnose System Inefficiencies

The data trending function of the Frick ECS system provides operators and managers with historical
system information which is easily interpreted and disseminated. The system logs all input information to
data files which can be plotted over varying time intervals as shown in Figure 12. Operators can use the
data trending to diagnose system problems by analyzing trends in system and equipment operation. The
operator may pinpoint the source of the problem by identifying surges and spikes within the trend. The
ECS system is also equipped with data logging functions which provide managers with operational infor-
mation in tabular report format. This information can be used to effectively plan maintenance projects and
procedures which can lead to increased system efficiency and minimize costly equipment downtime.

Frick’s refrigeration control group has more than 15 years experience in computerized refrig-
eration system control design. The group has invested thousands of hours to develop custom ECS
refrigeration control systems that optimize plant performance while minimizing power usage. The
Frick ECS system controls the refrigeration equipment to maintain design temperatures while pro-
viding operators with necessary information to properly diagnose system problems. The ECS con-
trol system is backed by lifetime remote diagnostics and support. Which only proves.......

you can't beat the system when it's all Frick.

Windows is a registered trademark of Microsoft Corporation.
Mistic is a registered trademark of OPTO 22.
ULand cUL are registered trademarks of United Laboratories. E90-900 ECS/FEB 99