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Tomislav Spoljaric
Polytechnic of Zagreb
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EN ENO S
MI110
B
w.f. 1
EN ENO
A>B
Figure 10. Multiplier block for assigning a percentage priority to
MI104 A probe 1
EN ENO EN ENO
D# 990 B
ADD LINEAR
D Y
MI120 A
MI130
TD0 MB6
X
[00:00:02.00] hum.pr.fail MI121 B
S MI122 C
Figure 8. Comparison block for triggering an alarm in a case of Figure 11. Addition of three values and linearizing the
humidity probe failure summation
D. Subroutine 2 – timers F. Subroutine 4 – regulation and writing to outputs
In this subroutine a block called LD TP (load In regulation subroutine first networks define the
timer) is used three times with preset values situation when a process is disabled. Alarm
(refrigeration, defrost and alarm reset period). One triggering and manual disabling of bit that starts the
such block is shown on Fig. 12. process (via HMI display or physical input) are
responsible for this part of code. All process bits and
EN ENO
timers are reset when these conditions are met.
LD TP
MB4 MB38
TD14 Start bit alarm stop bit
A B ML6
[06:00:00.00] R
MB40
Figure 12. Load timer block for refrigeration time
refrigeration bit
R
Operand A contains value from address TD14
with preset value that equals to 6 hours and moves it MB41
Defrost bit
into operand B on address ML6 which will be
processed in HMI display subroutine. ML6 is 32-bit R
TD15 MB41
I1 [00:30:00.00] Defrost bit
compressor fail
P R
I2 MB40
evaporator fail refrigeration bit
S
I3
heater fail Figure 15. Continuous cooling cycle
EN ENO MB41 O2
ADD Defrost bit heater output
MI113 MI25
A C R
reference ref+dT EN ENO
MI12 A >= B
dT B
MI103 A
EN ENO MI28
Tgref+2 B
ADD
MI25 MI26
A C
ref+dT ref+dT+dTs
Figure 17. Regulation process for defrosting
MI13
dTs B
MB40
G. Subroutine 5 – HMI display
O0
refrigeration bit compressor output This subroutine is used for loading and receiving
S
EN ENO
data blocks such as memory integers, memory bits
A>B
and output status into a graphical interface via HMI
MI130 A
display. In this article a PLC+HMI all-in-one device
MI25
ref+dT B V430-J-RH2 was used and a graphical interface was
MB40 MB7 O0 programmed in same software package as is a
refrigeration bit temp.pr1.fail compressor output
S
LADDER program. On Fig. 18 a monitoring screen
EN ENO
A>B
setting is shown. On Fig. 19 alarm screen setting is
MI100 A MB16 shown.
mode 2
MI26
ref+dT+dTs B
MB8
temp.pr1.fail
EN ENO
A>B
MI101 A
MI26
ref+dT+dTs B
MB9
temp.pr1.fail
EN ENO
A>B
MI102 A
Figure 18. Monitoring screen on HMI display
MI26
ref+dT+dTs B
MB40 MB16 O0
refrigeration bit mode 2 compressor output
EN ENO R
A <= B
MI130 A
MI25
ref+dT B
temp. probe 1
Physical input reading hum. probe
defrost probe
Subroutine 2 – timer definition
Storage section 1
temp. probe 2
Subroutine 3 – alarms definition
Evaporator section
Main routine
Subroutine 4 – regulation and
Storage section 2
6500mm
outputs management
temp. probe 3
...
Independent
Figure 20. Program flow diagram of a LADDER solution to a
temperature
simple cooling process with multi-probe monitoring and control measurement points
A. Cold room description Figure 21. Disposition of a cold room used in testing
Described program was tested in a real cold TABLE I. WEIGHT FACTOR ASSIGNMENT
room control system used for storage of
pharmaceutical and medical products, with 85% of Room probe (address) Weight factor (address)
its storage capacity fulfilled. Dimensions of a room Temperature probe 1 45% (MI110)
(MI100)
and placement of various equipment is shown on
Temperature probe 2 30% (MI111)
Fig. 21. Independent temperature measurement was
(MI101)
done with IR thermometer with ±1% accuracy Temperature probe 3 25% (MI112)
deviation for ambient temperatures above 0°C (MI102)
(Fluke® 568). Independent measurements were first
used for determining the best place for probes. B. Cold room in operation – testing description
Afterwards, with cold room in operation, Testing period lasted for 10 hours (600
independent measurements were used for minutes). Temperature measurement resolution was
determining the deviation between storage section 5 min per reading. During a testing period, one
temperature and temperature read by the PLC defrosting operation occurred (at 360th minute) and
probes. lasted for 10 minutes. Starting temperature was
Since a multi-probe monitoring and control in 16°C. Doors were opened three times: at 160 th
described way was implemented in real cooling minute, 320th minute, and 5 minutes before the
system, first task was to find appropriate weight ending of a test, and they were left open for 10
factors for probe priority assignments. After few minutes. During these periods independent
tests, weight factor of 45, 30 and 25 percent were measurements were taken in storage places (as
used as satisfactory when parallel temperature shown in table II). Deviations were mostly below 6%
measurement tests were made. Weight factor was with few peaks above that percentage. Also opening
chosen smaller with distance of installed probe the door of room resulted in higher temperature in
farther from the entry door, since the cold air tends space closer to the door, because the cold air in that
to flow out of the room when entry door opens. This place got out first. This resulted in higher
makes the temperature of the space closer to the temperature reading from temperature probe 1.
entry door higher than the rest of the room with These peaks in readings are shown on Fig. 22.
opened door. With that in mind, a higher priority is
When temperature rose above 6°C, regulation
according to room temperature probe 1 took place. It
lasted until reading from mentioned probe fell under
2°C. Then, after reading probes 2 and 3, and given a
satisfactory input under 6°C to PLC from each
probe, a three probe regulation was restored. Results
can be seen on Fig. 22 and Fig. 23. Regulation probe
is the term which defines the measuring value.
According to difference between this measuring
value and temperature reference system regulation is
set. Regulation probe can be presented by each of
temperature probes (if one of them deviates above
reference and hysteresis) or by mean value
calculation with weight factors which includes all Figure 23. Regulation probe and cooling/defrost state readings
during the testing period
three probes’ readings, as described in previous
section.
Compressor states in cooling mode of
operation and door status is shown on Fig. 24.
Temperature movement in higher peaks can be seen
as result of opened door. Compressor state according
to regulation probe measurements shows satisfactory
operation of compressor and with it the operation of
other refrigerating elements of the system.
TABLE II. REGULATION PROBE DEVIATIONS FROM
INDEPENDENT MEASUREMENTS
measurement 1 [°C]
measurement 1 [%]
measurement 2 [%]
measurement [min]
measurement 2[°C]
Regulation probe
Deviation of reg.
Deviation of reg.
Time point of
Temperature
reading [°C]
probe from
probe from
V. CONCLUSION
This type of control has proven to be a
160 5 5.2 3.17 5.1 1.19 challenge since control with more than two probes
165 6.4 6.5 0.85 5.8 -10.01 has not yet been implemented in standard
170 8.7 8.7 -0.51 8.5 -2.8 refrigeration regulators. Installed PLC that was
320 4.3 4.5 5.76 4.2 -1.29 described in article has also proven to be on a
325 5.8 6 3.18 5.5 -5.42 satisfactory level according to task given to it. But
330 9.5 10 8.9 8.9 -6.02 even with low cost PLCs, such as one used in this
595 6.2 5.9 -4.3 6 -2.67 case, a price for such control equipment presents a
600 8 8.3 3.23 7.6 -5.47 high demand for end user. Standard refrigeration
controllers are low cost and storage systems usually
do not demand regulation via more than two probes.
This is the main reason why PLCs are not present
more often in refrigeration market.
Trending time-temperature curves in form of
graphs can be also monitored, but in these article
they were not presented since BMS system which
receives data via MODBUS communication
protocol covered that area of monitoring in testing
system. In local monitoring mode these trend curves
can be very useful for end user.
Further possibilities include installment of
frequency converters on fans for fine regulation of
speed and with it a fine regulation of condensing and
Figure 22. Readings from three temperature probes during the suction pressure levels. Indirectly, this means a fine
testing period regulation in temperature may be obtained with these
devices. Since heuristic approach to weight factor
definition was used in testing it would also be
interesting if weight factors could be obtained using
intelligent software systems used for data
processing, such as fuzzy control or neural networks,
but this research also requires adequate time and
finances and with little possibility of significant
development in accuracy.
Described system that was installed in a real
cooling system, a cold room used for storage of
pharmaceutical products, was inexpensive and
challenging. And today it is very successful in
playing a part in regulation of a simple, yet
demanding, cooling process.
REFERENCES
[1] “SM2 Cold Rooms, Pliva: Strojarski projekt – tehnički opis
rada regulacije i nadzornog sustava”, project’s technical
description, Frigo-Ing d.o.o., Kašina, 2015.
[2] “Refrigeration – An Introduction to the Basics”, lecture
notes, Danfoss, Nordborg, 2007.
[3] Jagetić G., Habazin M., Špoljarić T., “PLC/SCADA systems
in automation control design for individual quick freezing
process in cooling tunnels”, 38th International Convention,
MIPRO, Opatija, 2015.
[4] Špoljarić T., Fruk M., Vujisić G., “Program Solutions for
The Complex Cooling Process Via LADDER Logic”, 37th
International Convention, MIPRO, Opatija, 2014.
[5] Vision OPLC: technical description, www.unitronics.com
[6] IO-PTx module: technical description, www.unitronics.com