BTC-automation

Heat supply process automation and visualization (SCADA) in a timber factory by using DANFOSS ECL Comfort 200/300.(SIA TROJA) (Troja, JSC)

Used controller: Danfoss Comfort, Lon Work.

Used visualization program: based on General Electric Cimplicity .

This technology concerns heat supply process automation and visualization on a timber factory. Hot water and heat supply regulating loops were connected to the automatic control system. Danfoss Comfort 200/300 controllers were used for the objects automatic regulation. All these controllers and 3 computers were connected with a help from Lon Work net. Using computer programme executing mechanisms can be switched on/off, regulating parameters and rules can be changed (for example, shifting from day to night regulation mode). You can also save and view in graphs and tables all the data about heat supply parameters, and record and save warning and alarm notices.

Applying of such a system allows factory to optimize costs related to heat energy supply.

Detailed description of the system.

The system consists of the following objects:

Computer with visualization and controlling programme and LON net interface card.
Allocation board of the workshop, were are two Danfoss ECL300 controllers, safety, communication and indication elements, as well as specialized LON controller with management logics and contacts servey programme. Cables from the workshop and store are coming to the board for valves automatics, engines, circulation pumps, regulation valves, temperature sensors and fire signalisation.
Cauldron allocation board, were there are two Danfoss controllers - ECL200 and ECL300, safety, communication and indication elements, as well as specialized LON controller with contacts servey programme. Cables comes on the board from the heat supply, hot water and air machine water loops to circulation pumps, regulation valves and temperature sensors.
All these objects are connected with communication cable and video Lonworks information net.

1. Computer with visionalizing and controlling programme

Computer has installed "Eschelon" LON net interface card PCLTA-10, and LNS DDE SERVER programme of the same company, which allows to exchange information with controllers, connected to LON net, and to get and send information to another programme - visionalizing and management programme. All the programmes work in Windows NT.

Because individual controllers are used for executing of the most important system functions, the system is valid also in case if computer programme somehow is faulty.

2. Allocation board of the workshop

2.1 Controlling of the air machine of the workshop

Danfoss ECL300 type controller with C14 programme card provides air temperature regulating function (on the left side of the allocation board panel). Two temperature sensors are connected to the controller: air flood exit and heat shift for water going backwards. C14 programme provides the system resistance from freezing (if a heat shift backwards temperature decreases lower than 6°) and some other functions described in Danfoss C14 card documentation.

Safety, communication and indication chains are providing extra functions:

Water circulation pump safety and switching on indication;
Engine safety and switching on indication;
Circulation pump status (on/off), engine status, and also regulating valve movements defining.

2.2 Management of the store air machine

All functions are the same as for the air machine of the workshop management. Danfoss ECL300 type controller with C14 programme card is on the right side of the workshop allocation board panel.

2.3 Specialized LON controller

Controller with 15 numbers enters, which is connected to the status and safety contacts, workshop and store gates opening signalisation contacts, fire signalisation contacts, fire alert switching off button and warning of freezing signalisation contacts. Manual locks are maintained on workship and store gates. They allow to switch on air when the gates are closed and to switch it off when the gates are opened. The controller executes the following functions related to the workshop as well as to the store hot air machines:

periodical contacts condition servey;
sending the information via LON net to the computer visionalizing and management programme;
when the gates are opening, the circulation pump and machine switch on. ECL300 controller is switched on in automatic mode (air flood temperature regulation and other functions executing according to C14 programme).
when the gates are closing, the circulation pump switches off. ECL300 controller is switched on in manual mode (the programme work is stopped). After 45 seconds machine switches off.
When the gates are closed the circulation pump switches on every 30 minutes for 2 minutes to maintain temperature in the heat shift machine.
When the command is got from computer controlling programme via LON net, summer mode switches on. That means that all engines and valves are switched off, ECL300 controller remains on manual independent from the gates condition. The circulation pump switches on once during 72 hours, the valve is opened during 150 seconds, than it is closed during 150 seconds. After valve is closed the valve and pump are switched off. When computer sent the command, the summer functioning mode is cancelled and normal mode is activated.

If the fire signalisation contact reacts, ECL300 controller shifts to the manual mode and all the engines are switched off, if the gates are opened in the moment when signalisation contact reacts. The gates opening contact signal is ignored. This kind of mode remains al long as the button inside the allocation board is pressed.

3. The home allocation board of the cauldron

3.1 The premises heat supply cauldron and hot water supply

Danfoss ECL300 type controller with C66 programme card provides all the main management and regulation functions (on the right side of the board). Five temperature sensors are connected to the controller: open air temperature, apartments temperature, heating supply water forwards and backwards, heating water forwards. Above all the controller contains extra analogous entrance module, which is connected to the moisture sensor of the 2nd floor and the temperature sensor. All functions provided by ECL300 controller with its programme as well as regulating parameters and possibilities are described in Danfoss C66 card documentation.

Safety, communication and indication chains are providing extra functions:

Hot water circulation pump safety and switching on indication;
Heating circulation double-pump power safety, each pump switching on indication and un thermo-safety workability indication, as well as possibility to activate one from pump manual-work modes, or to let shift the pumps using computer programme;
Circulation pump status (on/off), heating double-pump thermo-safety contact status, and also regulating valve movements defining;

3.2 Air machine hot water loops

Danfoss ECL300 type controller with P16 programme card provides all the main management and regulation functions (on the right side of the board). All functions provided by ECL200 controller with its programme as well as regulating parameters and possibilities are described in Danfoss P16 card documentation.

Safety, communication and indication chains are providing extra functions:

Hot water circulation pump power and switching on indication;
Circulation pump status (on/off), heating thermo-safety contact status, and also regulating valve movements defining.

3.3 LON specialized controller

Controller with 13 numbers enters, which is connected to the status and safety contacts. The controller executes two functions:

periodical contacts condition servey;
sending the information via LON net to the computer visionalizing and management programme.

Service of the equipment

All operations with ECL controller are described in corresponding Danfoss programme documentation.

The significance of signalling lamps and locks which are situated on front panels of the boards, is obvious and does not demand any explanations.

The locks situated on the walls of the boards, are the holes, which are used for feeding for all board elements. We recommend not switching off without a special need the board feeding. When a system operation should be stopped (heating, hot water, or air machine hot water), for example, on the weekend, shift the ECL controller using corresponding button to switched off mode (ref. Danfoss programme description). After some time the circulation pump will switch off and programme will stop its operation. To restore the system operation, shift the ECL controller using the same button to auto- mode.

If feeding was switched off, than all the equipment starts working immediately after switched on (for 1 degree forwards - pause of 5 seconds - and backwards).

Visionalizing and management programme description

Visionalizing and management programme is designed basing on "GE Fanuc" company programme package Cimplicity HMI in Windows NT. It allows showing graphically on the display the most important parameters of the system and executing elements conditions, to change regulators settings, to archived the most important operation parameters of the system, to look trough and print operation data of the previous period.

From the operator's point of view the programme complex contains 3 parts: the first one executes exchange of the data between the equipment of the system, which are connected to LON net. These are "Eschelon" company LNS DDE server. The second part is "Cimplicity HMI" substance, that is getting (and sending) data from LNS DDE server and save them in its data base. The third part - Visionalaizing - allows to abserve process, to change settings, to look through archive data, to print reports. The 1st and the 2nd parts have to operate in non-stop mode. The 3rd part may be missed and stopped any time. Each of the three parts is started with its icon from Windows deck top.

The archive process of the data base has Microsoft Access structure (mdb), that allows the analyse data with Microsoft Office instruments - Excel and Access.

The programme start screen air machine and heating visionalizing see above in the description.