Operating Guide for the Air-Conditioning Automatic Control System at Anhui Huamao’s No. 8 Factory

 

1.  Control cabinet, PLC workstation, server

The air-conditioning automatic control system at Huamao’s No. 8 Factory provides one control cabinet for each air-conditioning unit, as follows:

MCC1, MCC2、MCC3、MCC4、MCC5、MCC6、 MCC7,

MCC9, MCC10、MCC11、MCC12、MCC13 MCC14

2 high-performance units PLC CX9020 Installed separately Control cabinet MCC7 ， MCC9.

The three human-machine interaction workstations are each installed near KT7. ， The auxiliary room and workshop office of KT3.

A server is installed in the computer room of Factory No. 8.

 

2. 1# PLC is installed in MCC7.

Name: CX-3591F8

NET ID: 5.53.145.248.1.1

IP address: 192.168.1.1

 

This PLC Through the bus control module EK1110 Through EtherCAT Fieldbus with 100MBIT/S Communication rate and separately installed in the control cabinet MCC7、6、5、4、3、2、1 The one internally coupled by the bus module BK1150 Digital input module KL1809 Digital Output Module KL2809，0-10V Analog Output Module KL4408， 4-20 mA Analog Input Module KL3054， The distributed input/output module group, composed of Pt1000 temperature resistance modules, performs bidirectional data communication.

 

3. The #2 PLC is installed in MCC9.

Name: CX-3591FC

NET ID: 5.53.145.252.1.1

IP address: 192.168.1.2

 

This PLC Through the bus control module EK1110 Through EtherCAT Fieldbus with 100 Mbit/s Communication rate and separately installed in the control cabinet MCC9、10、11、12、13、14  The one internally coupled by the bus module BK1150 Digital Input Module KL1809 Digital Output Module KL2809，0-10V Analog Output Module KL4408， 4-20 mA Analog Input Module KL3054， The distributed input/output module group, composed of Pt1000 temperature resistance modules, performs bidirectional data communication.

 

4. PLC controller CX9020 (Substation)

The runtime indicator is green.

By disconnecting and opening the micro-QFD inside the control cabinet. can be realized Reset and restart of the PLC controller.

 

5.  The air conditioning automatic control system server has 2 built-in. Block network card

The IP address is 192.168.1.100 The network card is responsible for communicating with 2 Taiwan PLC data communication via switching,

The IP address is 192.168.19.111 The network card is responsible for communicating with MES system communication, providing remote services.

Remote login address: 192.168.19.111

Password: p@ssw0rd

 

6.  Three-terminal human-computer interaction workstation IP Address

192.168.1.20     

192.168.1.21  

192.168.1.22

It should be noted that the workstation does not undertake control tasks; automatic control is handled by the CX9020 PLC controller installed in the control cabinet. The workstation’s task is to serve as the human-machine interface for the control system, displaying the following parameters:

All digital input and output signals,

Digital input calculation values (such as the alarm status of each motor),

All analog signal inputs and outputs (such as temperature and humidity signals, differential pressure signals, damper actuator positions, variable frequency drive speed control signals, etc.),

Simulated calculation values (such as absolute humidity, dew point temperature, enthalpy, etc.),

Setpoint (such as temperature, humidity, pressure, etc.),

PID parameters,

Timer parameters,

Provide process display,

Reports, real-time and historical curves for parameters, a list of current or historical alarm information, and the corresponding printing function.

Wait a minute.

 

7.  Control cabinet panel

The control cabinet panel is equipped with:

3-position self-resetting power undervoltage protection knob SV,

2-position self-controlled on/off knob SS

Power Supply Undervoltage Monitoring Indicator Light H0

The undervoltage monitoring indicator light H0 In the on and lit state, directly... 2 Position-controlled start-stop knob SS spin to [Start] Location: The air-conditioned room has entered automatic control mode.

 

Put 2 Position-controlled start-stop knob SS spin to [Stop] Location: The air-conditioned room has exited automatic control mode.

 

The undervoltage monitoring indicator light H0 When the device is in the off state, it indicates that the control power supply has been interrupted at some point, preventing the automatic control system from starting up. You must... 3 The position self-resetting knob, after initiating the position jog, illuminates the undervoltage monitoring indicator light. H0 , only then can it 2 Position-controlled start-stop knob SS starts the air-conditioned room to operate automatically.

 

This self-controlled startup method can effectively prevent power outages in the workshop; when power is restored, all motors in the air-conditioned rooms will start up simultaneously.

 

8.  Power frequency / Variable frequency

  The control cabinets for fans, pumps, dust collectors, and dust-collection fans will be provided by the owner. All electrical cabinets equipped with variable-frequency drive circuits will include a power-frequency drive bypass. After the automated upgrade, a new [automatic] feature has been added. / Disconnect [Manual] Three-position selector switch.

When the three-position selector switch is located at... [Automatic] In terms of location, when the system is operating in automatic mode, the control system first selects to start the variable-frequency drive (VFD) circuit. The VFD speed is set by the automatic control system. If at this time the system receives a VFD fault signal or fails to receive a running signal from the VFD, after a delay-based judgment, the control system first disconnects the VFD start command, then delays and activates the mains-frequency bypass circuit. At the same time, an alarm message for the VFD circuit will pop up on the workstation’s alarm interface. Upon receiving the VFD circuit alarm message on the workstation, the operator should first go to the field to reset the alarmed VFD, restoring it to normal operation. After returning to the workstation, click on the icon next to the faulty motor symbol in the process flow diagram. [ R 】 The command button will cause the control system to switch back to the variable-frequency drive circuit.

Set the three-position selector switch to [Disconnect] The unit cannot be started, whether in the variable-frequency circuit or the power-frequency circuit.

Set the three-position selector switch to [Manual] Position: Another 2-position selector switch on the control panel is set to the ON position. [Variable Frequency] Location: Operators can start and stop the frequency converter using the start/stop button on the control cabinet panel, and adjust the frequency converter’s speed by means of the potentiometer on the control cabinet panel.

Set the three-position selector switch to [Manual] Position: Another 2-position selector switch on the control panel is set to the ON position. 【Power Frequency】 Location: The operator can start and stop the motor using the power-frequency start/stop buttons on the control panel.

 

9.  Workstation Operation

Double-click the workstation desktop. [Textile Air Conditioning] A quick icon allows you to launch and run the human-computer interaction program. This system features a three-level password system, with levels 2... Level; 1 Level; 0 Level. You can log in or log out via the [Account Management] menu. After entering the menu, If no operation is performed for 15 minutes, the system will automatically log out of the password account.

The visitor system for accounts without a logged-in password refuses to execute any parameter modification commands, but it can display various pages and perform print jobs.     

 

Level 2 password permissions ： hmyonji

Only the DO items in the data list can be modified, allowing remote manual forced control of the motor’s on/off status.

 

 1 Permissions for level passwords ： hmzhoji

Modify the DO in the data list. Item: Allows remote manual forced start and stop of the motor; modifies data lists. AO Item: You can remotely and manually force the setting of the damper opening and the output speed of the frequency converter; modify the data list. TI Item: You can modify the start-up and shut-down delay times for each motor, as well as the on-off cycle duration for the water filter and dust collection fan, among other settings. Set the temperature, humidity, and pressure on the process interface. , and Exit the running monitoring program. 。

 

Permissions for Level 0 passwords ： xxxxxx

Modify all items in the data list, as well as... Exit the running monitoring program. This password should be used with caution. For example, incorrectly modifying the sign of the PID proportional parameter will cause the system to adjust in the opposite direction, resulting in operation that deviates from the target value.

 

10.  Start/ Exit the monitoring program

Click on the desktop. [Textile Air Conditioning] The shortcut icon can immediately launch the central control computer. (Main site) The monitoring program on the screen. Click the menu item. [Account Management] , Log in 0 Level or 1. Enter the password, then click the menu item. [Exit] You can then exit the monitoring program.

 

11.  Workstation ( Communication between the master station and the PLC controller (slave station)

In case of a central control computer (Main site) The surveillance footage cannot display real-time data.

First, exit the monitoring program.

Check whether the indicator light on the main station network card is flashing.

Check whether the network cable plugs on both the main station and the substation sides are loose or disconnected.

Check the main station IP. Has the address been rewritten?                                                           

 

12. DI List

Digital input signal

“Automatic on/off switch”—when the manual mode is enabled, the current value is replaced by the manual setting, thereby enabling remote system startup.

The current value of the “fire alarm signal” is [1], and this air-conditioned room will be shut down.

 

Attention, For equipment driven by inverters, for some reason the inverter’s operation signal has failed to return. (Current value For 【 0 】), the control system’s output frequency signal will return to zero, To maintain normal system operation, the inverter’s running signal must be manually set to [ 1] The frequency output of the control system will return to normal.

 

13. DO List

Digital output signal

Such as “1#” Dust collection fan ”， Manually set the value to 【 1 】, set the manual condition to 【 1 】, then the current value is 【 1] The dust collection fan start command is issued;

Set the manual value to [0] 】, set the manual condition to 【 1 】, then the current value is 【 0], the dust collection fan stop command is issued.

 

14. DX List

Intermediate calculated value of digital signals

Such as “1#” Fan failure,” current value is 【 1 ], indicating that the fan start signal has been sent, but the running signal has not yet returned.   The color turns red.

The current value can also be manually set by defining a manual value and applying manual conditions.

 

“Air supply fan running,” current value is 【 1】The water pump can only be turned on at this time.

 

“Start the ice machine.” When the enthalpy of the fresh air exceeds the dew-point enthalpy calculated based on the set temperature and humidity values for the workshop, after the delay period following the ice machine’s activation, “start the ice machine.” The current signal value has changed 【 1], the air-conditioned room sends a request to the chiller plant to start the cooling system.

 

“Mechanical cooling mode,” when... Start the ice machine. The current signal value is 【 1 】, Moreover, when the chilled water supply tank temperature falls below the calculated dew point temperature, after the “mechanical cooling mode start delay” has elapsed, the current value of the “mechanical cooling mode” is 【 1] Only then can the “mechanical cold spray outlet temperature controller” be started, and its output can be used to adjust the opening of the cold water valve.

 

15. TI Timer List

Can be modified freely, unit: Second ”。

Fan start delay

Blower start delay

Fan delay

Fan shutdown delay

Dust collection fan cycle on time

Dust collection fan cycle shut-off time

Dust collection fan periodic on-off time

Ice machine start delay

  Ice machine stop delay

Refrigeration system start/stop

DX request signal generation /Disappearance delay

Mechanical cooling mode start delay

Mechanical cooling mode shut-off delay

Delay for entering/leaving the cold water valve adjustment mode

 

16. AI Analog Input List

Sensors for temperature, humidity, pressure, liquid level, etc. / The transmitter collects continuously varying on-site data. 4-20mA/Pt1000 signal.

  It should be noted that the fresh air temperature and humidity are parameters shared by all air-conditioned rooms. However, due to certain factors, these parameters have failed to be transmitted to this particular air-conditioned room. In such cases, it is necessary to set manual values to ensure the system operates normally. When the air-conditioning system is in free-cooling mode and the chiller plant is not yet activated, You can set the manual values for the fresh air temperature and humidity parameters to lower levels, and set the manual condition to 【 1 ], informing the system that the enthalpy of the fresh air is lower than the dew-point enthalpy, thereby ensuring that the control system operates in free-cooling mode. The workshop temperature is regulated by adjusting the opening degree of the fresh-air damper.

When the air conditioning system is in mechanical cooling mode and the chiller plant is operational, you can set the manual values for the fresh air’s temperature and humidity parameters to higher levels and set the manual condition to [1]. ], informing the system that the fresh air enthalpy is higher than the dew-point enthalpy, thereby ensuring that the control system operates in a mechanically cooled state. The workshop temperature is adjusted by regulating the opening of the chilled-water valve.

Similarly, the chilled water temperature in the cooling station’s supply tank is a shared signal for all air-conditioned rooms. However, due to certain factors, this signal failed to be transmitted to one particular air-conditioned room, causing the chilled water temperature display to show 【0】. As a result, the system might switch from its free-cooling mode—where the room temperature is regulated by the fresh-air damper—to a mechanically cooled state regulated by the chilled-water valve. In such a situation, you can manually set a higher chilled water temperature value to enable the system to remain in the free-cooling mode, with the fresh-air damper still regulating the room temperature.

 

17. AO Analog Output List

0-10V/2-10V output signal to the frequency converter, damper actuator, and chilled water valve actuator;

You can set a manual value, with the manual condition being [1].

Set the inverter frequency

Air damper opening degree

Cold water valve opening degree

Fixed at the desired manual value.