Automatic and DDC Control Fundamentals and Energy Conservation For HVAC Equipment - Battelle - Compact

Automatic and DDC
Control Fundamentals Disclaimer

and Energy Conservation This presentation was prepared specifically for use as
college training material
material. It shall not be modified
for without the consent of the authors.
HVAC Equipment-Part 1
This presentation represents sponsored research
activities. Neither the Client nor Battelle warrants
the accuracy, completeness or usefulness of the
information. Reference herein to any specific
commercial i l product,
d t process or service
i b by ttrade
d
names or manufacturer does not constitute an
endorsement or recommendation.
PNWD-SA-8834
1-1 1-2
DDC Controls and Energy Conservation for Part 1

HVAC Equipment
Eq ipment - Agenda HVAC Control Principles
1. Introduction of DDC Controls Project 1. Intent of Battelle Pacific NW Division involvement
2
2. HVAC C Control
t lP Principles
i i l
2. Purpose of Controls
3. Communication Standards and Networks
4
4. Vendor Examples of DDC Software Programming and 3. Keyy Components
p of Control Systems
y
Operator Interfacing
4. Control Loops, Open vs. Closed Loops
5. Typical Rooftop and Central AHU HVAC Control
Systems and Applications 5 Terminology
5.
6. System Maintenance and Service of DDC Controls 6. The Control Cycle and Control Actions
7. Avoiding
g Common Control Problems and Fixing g the
Problems 7 The
7. Th Energy
E Sources
S for
f Control
C t lSSystems
t
8. Calibrating and Verifying Energy Savings of the DDC 8. DDC Point Types
Controls
PNWD-SA-8834 PNWD-SA-8834
1-3 1-4
Part 2 Section 1
Control Applications, Networks, Introduction of DDC Controls Project
Programming, Maintenance, and • Purpose of this project is to provide HVAC
Energy Savings educational
d ti l materials
t i l tto WWashington
hi t St State
t
1. DDC Control Applications community colleges to educate students who have
chosen or may chose career paths related to HVAC
2. DDC Networks and Architecture servicing and building energy management fields
3. Communication Standards and Networks
4. Vendor Examples of DDC Software Programming
and Operator Interfacing
5. System maintenance and service of DDC controls
6. Using
g DDC controls to save energy
gy
1-5 1-6
Section 2 Section 3
HVAC Control Principles K
Key Components
C t off a C
Control
t l
The Purpose of Temperature Controls System Include:
• Control systems are the “brains” of HVAC equipment to
maintain
i t i h human comfort.
f t Pi
Pictured
t db below
l iis an AHU th thatt
serves only one zone. This type of AHU is called a single
zone AHU. In the example, a temperature sensor (stat) sends
a signal
i l tto a control
t l panel,
l which
hi h sends
d a signal
i l tto a valve.
l
Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric

1-7 1-8
Sensors Sensors
• A sensor monitors and measures a variable. The
HVAC variables are temperature, humidity, flow, and
Modern HVAC Sensors Include:
pressure Different types of signals are produced by
pressure.
• Humidity and temperature transmitters different types of sensors. They include:
• CO2 for indoor air quality (IAQ) utilizing – Electric sensors
d
demandd control
t l ventilation
til ti
• Power meters – Pneumatic sensors
• Branch circuit monitors – Electronic sensors
• Energy meters
An example of a sensor is shown here. While it may

appear to be a thermostat, it is a remote sensor with
a remote setpoint dial.
dial The controller is in another
Courtesy Veris Industries
location. Courtesy TAC Controls/Schneider Electric
1-9 1-10
Pneumatic Sensors/Transmitters Electronic Sensors Include:
• Pneumatic controls sensors or transmitters • Resistance sensors are resistance temperature

sense the variable and produce a 3 psig to 15 devices (RTDs)
(RTDs), and are used in measuring
psig (pound per square inch, gauge), [20 kPa temperature. Examples are Balco elements, copper
(kiloPascals) -105 kPa] signal over a particular platinum, 10K thermistors, and 30K thermistors.
transmitter's range. • Voltage sensors could be used for temperature,
humidity and pressure. Typical ranges are 0 to 5
Vd (V
Vdc (Volts
lt di
directt current),
t) 1 tto 11 Vd
Vdc, and
d 0 tto 10
Vdc.
• Current
C t sensors could
ld b
be used
d ffor ttemperature,
t
humidity, and pressure. The typical current range is
4 to 20 mA ((milliamps).
p )
Courtesy Johnson Controls
1-11 1-12
1000 (Ohms) Balco PTC
Electronic Temperature Sensors Comparison
p of Common Temp
p Sensors
• The resistance outputs of a electronic Balco temperature
sensor follow the diagrams below:
• When 1000 ohms is measured across the Balco element, the

temperature is approximately 70°F (21°C).
(21°C) As the temperature
increases, the resistance changes 2.2 ohms per 1°F (3.96
ohms per 1°C). In a Balco temperature sensor, as the
t
temperature
t increases,
i the
th resistance
i t increases
i proportionally
ti ll
in a positive direction. This is known as a positive temperature
coefficient (PTC) sensor. However, many temperature sensors
are considered
id d ththermistors,
i t andd perform
f as N
Negative
ti
temperature coefficients (NTC). Courtesy Omega Controls
1-13 1-14
Controllers Can Include: Controllers basic principles

Electric Controls Pneumatic Controls the controller receives the input
And processes an output
DDC
Controls
Electronic Controls Courtesy Johnson, Honeywell, and Alerton Controls

1-15 1-16
Electronic Control System
y Pneumatic Controller System
“Branch”
Branch or Control Damper
Pressure
Sensor
Damper
Controller Operator
Filter
“Main” or Supply
pp y
Pressure
Pressure
Compressor Regulator
Valve
Actuator Thermostat
Valve
Courtesy Honeywell Controls Courtesy Northwest Energy Efficiency Council

1-17 1-18
Controller Action-Direct or Reverse

The DDC controller receives the input Illustration
from the sensor, performs a logic
function and processes an output
function,
Courtesy DDC Online Org Courtesy Honeywell Controls

1-19 1-20
Controller Direct Action-Illustration Controller Direct Action-Illustration
• This relationship between the input to a controller

(temperature) and its output (current) can be
displayed on a graph as follows:

1-21 1-22
Controller Reverse Action

Action-Illustration
Illustration Controller Reverse Action
Action-Illustration
Illustration
• This relationship can is displayed on a graph as
follows:

1-23 1-24
Controlled Devices Controlled Devices
Valves
Diverting Valve
Control Valves Mixing
g Valve
– two-way Control Valves

Used with differential pressure (DP) sensors and VSD pump
systems on primary and secondary loops
– three-way (mixing or diverting)
– Pressure
Press re independent control valves
al es
Automatic dampers
Damper operators
VSDs: variable speed drives Typical Single - and Double-Seated Typical
T i l Three-Way
Th W Mixing
Mi i
Two-Way Valves and Diverting Valves
Courtesy Belimo Courtesy Belimo
1-25 1-26
The Present Control Systems

y Examples of 2-Way and 3-Way
Use control valves that are: Control Valves
•Pressure
Pressure independent control valves
•No Cv required, reduced pumping costs, higher
efficiency, easy to balance.
Courtesy Flow Control Valves

Northwest Energy Efficiency Council
1-27 1-28
Dampers: Types, Actuators, Economizer Damper Actuator Types
and Characteristics are either:
– Economizers on many central AHUs are
custom ordered
custo o de ed for
o the
t e job specific
spec c Pneumatic Electric Electronic
requirements
– Economizers on packaged RTUs are
normally ordered as an option with the
package
– Control Dampers Can Be Either:
P ll l or opposed
Parallel dddampers
Parallel Blade Opposed Blade

1-29 1-30
Economizer Damper Actuators Parallel Blade Damper Characteristics

will have either direct connect actuators bolted have p
poor linear control
directly to the damper or they will be installed with a
shaft and linkage arrangement (more prone to fail)
Direct Connect Actuator Damper Connected to Actuator

PNWD-SA-8834
Via Shaft and Coupling PNWD-SA-8834
Courtesy T.A. & Co.
1-31 1-32
Opposed Damper Characteristics
have better linear control Damperp Actuators can be Controlled by y:
• Voltage (0-10Vdc or 2-10Vdc)
• Current (4-20mA)
• Floating
Fl ti pointi t (binary
(bi pulse
l tto open or close)
l )
• PWM-pulse width modulated
• Resistance (0-135
(0 135 ohms)
Courtesy T.A. & Co.

Example of analog control using 4-20mA or 2-10Vdc
Courtesy Belimo
1-33 1-34
Electronic Variable DDC control systems have variable

F
Frequency Drives
Di (VSDs)
(VSD ) f
frequency drives ((VFDs)) as
standard equipment on:
•Vary frequency of motor to control speed • Cooling

C li towers
• AHU’s and VAV fans
•Often called VSDs,
VSDs VFDs
VFDs, or ASDs
• Pumps
• Chillers
1-35 1-36
Review of the Key Control
Variable Speed Drives Components
Exercise-identify the sensors, controllers, and
controlled devices
Courtesy TAC Controls/Schneider Electric

Courtesy ABB Controls
1-37 1-38
Review of the Key

y Control Review of Control Action
Exercise-the
Exercise the control drawing below has a
Components direct acting controller, with a NO valve. Show
Exercise-connect the sensor, controller, and the correct action with arrows at each
controlled device in the proper order.
order componentt when
h usedd ffor cooling
li mode.
d
___________Acting
Courtesy Alerton and Belimo Courtesy TAC Controls/Schneider Electric and Belimo
1-39 1-40
Review of Control Action Review of Control Action
Exercise Circle the correct answer.
Exercise-Circle answer
Exercise-Circle the correct answer.

1-41 1-42
Review of the Key Control

Review of Control Action
Exercise-Circle the correct answer.
Components
Exercise-Identify the parallel vs. opposed blade
dampers and the 3-way mixing vs. diverting
_________________ _________________
Courtesy TAC Controls/Schneider Electric _________________ _________________ Courtesy Belimo

1-43 1-44
Section 4 Basic Closed-Loop-Example
The sensor feeds back to the controller
Basic Control Loop Principles
Controllers can be either
“ l
“closed”
d” or ““open”
”LLoop
– Closes
Cl lloops provide
id ffeedback-good
db k d controll
– Open loops have no feedback-poor control
Courtesy DDC Online Org

1-45 1-46
Closed vs. Open Loop Control

Open Loop Controls Illustration
have no feedback to the controller Notice, averaging bulb is closed loop in supply air,
but T-STAT between filter and coil is open loop.
Courtesy DDC Online Org Courtesy Northwest Energy Efficiency Council

1-47 1-48
Section 5 Setpoint
Control Terminology Setpoint is the desired condition of a variable that is to be
maintained, such as temperature. In the example below,
Setpoint, offset, and control point 75 degrees F F. is the room temperature setpoint that the
Throttling range building occupant desires.
Span
p and range
g
Authority
Calibration
Analog and digital
Thermostat as sensor-controller

1-49 1-50
Control Point and Offset Throttling

g Range
g
• The Control point is the actual temperature being sensed.
The control point (temperature) may not be on the setpoint, • System throttling range (STR) is the change in the
but instead may be above or below it. Simply stated, measured variable (i (i.e.,
e temperature) that causes
setpoint is what you want, while control point is what you the controlled device to travel from one end of its
get. Offset is the amount of difference between control
stroke to the other.
point and setpoint in a proportional control system
system. In the
example below, the offset is approximately 4°F.

1-51 1-52
Section 6 Control Cycle Graph
The Control Cycle and Control Action
•Two
T position
iti
•Floating action
•Proportional action
PI
•PI
•PID
Courtesy PECI Courtesy Northwest Energy Efficiency Council

1-53 1-54
T
Two Position
P iti C
Control
t l T
Two Position
P iti C
Control
t lR Response
Two Position control action chart (heating action shown)
Courtesy Northwest Energy Efficiency Council

1-55 1-56
Floating Action Control P
Proportional
ti lCControl
t l Action
A ti
Proportional Control Action
Courtesy Northwest Energy Efficiency Council Courtesy Northwest Energy Efficiency Council
1-57 1-58
Proportional with
PID-Proportional
p
I t
Integral
lCControl
t l (PI)
Plus Integral & Derivative
Proportional Plus Integral (PI) Control Action

Proportional Plus Integral Plus Derivative (PID) control action
1-59 1-60
Review of Control Cycles
Adaptive Control Exercise; study the drawings and identify
Adaptive loop tuning provides: the control loop types as either:
•Accurate, continuous loop control 2-position, proportional, or PI Control
•Faster tuning of loops for energy savings
•Less wear on valves, actuators, fans, pumps, dampers, _________________
VFDs, etc.
_________________

_________________
1-61 1-62
Review of Control Cycles Review of Control Cycles

y
Exercise; identify and circle the closed
loop vs. the open loop controls. Exercise; review the drawing and
identify setpoint, control point, TR,
and offset
offset.
Courtesy Northwest Energy Efficiency Council Courtesy TAC Controls/Schneider Electric

1-63 1-64
Review of DDC Terminology Section 7
Exercise; identify the missing terms Control Energy Sources
A power supply or source of energy is needed to
power the control system
system. Control systems use
either a pneumatic or electric power supply.
• Pneumatic controls use a compressed gas as a
source of energy, typically compressed air.
• Electric and electronic controls could be
powered by a variety of electrical power supplies
of either alternating current (AC) or direct current
(DC).
(DC)
• DDC-Direct digital controls are considered
electronically powered via a network of controls
controls.
1-65 1-66
Comparing Advantages
And Disadvantages Basic Pneumatic Control System
of pneumatics and DDC controls The Air Station Components
•Pneumatic control systems
• Low maintenance, ease of testing
• Hard to integrate into DDC systems
• Requires air compressor station
•DDC
DDC – Direct
Di t didigital
it l control
t l
• High accuracy
• Flexible,
Flexible easy to access
• Programmable
•Energy management considerations
• Easy to optimize, reduce kW peaks, schedule Courtesy Honeywell Controls
1-67 1-68
Conventional Pneumatic
Basic Pneumatic Control System
Control Systems
Requirements:
Ŷ Clean and dry air supply
Ŷ Pressure reducing valve
Ŷ Utilizes pneumatic controllers
Ŷ Pneumatic devices
1-69 1-70
Pneumatic Controls Include: Pneumatic Control of Heating

Coil Control with Reset
• Thermostats that can be either:
• Room type
• Dead band types
yp
• Dual pressure type
• Humidistats
• Receiver controllers
• Combine 2 sensors into 1 receiver with reset
setpoint options
• Utilizes either one pipe or two pipes
• Sensors
1-71 1-72
Pneumatic Control System
Accessories B i Pneumatic
Basic P ti Control
C t l System
S t
Pneumatic relays:
Ŷ Reversing relay
Ŷ High/low pressure selector
Ŷ Air motion
Pneumatic Switch
Ŷ Signal repeating EP-Electric to Pressure Switch
Ŷ Minimum position
PNWD-SA-8834
Ŷ EPs and PEs PE-Pressure to Electric Switch
PNWD-SA-8834
1-73 1-74
Basic Electric Control

Example of Pneumatic Controls
Courtesy LAMA Books Courtesy Honeywell Controls

1-75 1-76
Simple Electronic Control
Example
a peo of Electric
ect c Controls
Co t o s
S t
System
for Economizers
Courtesy Honeywell Controls

1-77 1-78
Example of Electronic Control for

Example of Electronic Control for Economizers with Differential Enthalpy
Basic AHU Economizer Control and CO2 Demand Ventilation Control

1-79 1-80
Section 8-DDC Point Types
Input
p and Output
p Point Types
yp Chart DDC Control System
Input Output
Two state information from the building Two state information from DDC field
Digital Input (DI) Illustration
into the DDC field panel panel to the building
Di it l
Digital
Switches: On/Off - fans, pumps, lights
Differential press/proof Open/Close, two position damper
Smoke alarms Control of two

two-speed
speed motors
Level alarm Energize/de-energize valves for
heat/cool changeovers
High/low pressure alarm
Filter status
Variable information from the building Variable information from the DDC
into the DDC control panel control panel out to the building
Analog
Temperature Room duct,

Temperature-Room, duct OSA Modulate valves
valves, dampers,
dampers actuators
Humidities-Room, duct, OSA Motor speed control – VSDs

Pressure-Static, velocity, total Modulate volume dampers
Flow rates-Water and air systems Adjust air pressure to pressure operated
devices
kWh power, volts, and amps Courtesy DDC Online Org.

1-81 1-82
DDC Control System DDC Control System

Digital Input (DI) Illustration Digital Input (DI) Pulsed Signal
Flow Switch Illustration
Flow Switch

Courtesy Verris Industries
1-83 1-84
Digital Output (DO) Illustration A l
Analog Input
I t (AI) Illustration
Ill t ti
Triac Type Digital Output with External Relay Transistor with Pilot Relay
Courtesy DDC Online Org. Courtesy DDC Online Org.

1-85 1-86

Analog Input (AI) Illustration Analog Output (AO) Illustration
g Air Flow in FPM
For Measuring For controlling
gap
pneumatic valve
Courtesy Dwyer Instruments. Courtesy TAC Controls/Schneider Electric

1-87 1-88
Analog g Output
p (AO)
( ) Damperp Actuators Example
p of DDC AHU Control
are controlled by either a voltage (2-10 Vdc) or Application with Point Types Identified
current (4-20 mA) signal from the controller
Courtesy Belimo Courtesy Honeywell Controls.

1-89 1-90
Exercise Exercise
Review of DDC Terminology Review of DDC Terminology

1-91 1-92
DDC Disclaimer
Control Fundamentals This presentation was prepared specifically for use as
andd Energy
E C
Conservation
ti college training material
material. It shall not be modified
without the consent of the authors.
for
HVAC Equipment-Part 2 This presentation represents sponsored research
activities. Neither the Client nor Battelle warrants
the accuracy, completeness or usefulness of the
information. Reference herein to any specific
commercial i l product,
d t process or service
i b by ttrade
d
names or manufacturer does not constitute an
endorsement or recommendation.
PNWD-SA-8834
2-1 2-2
DDC Controls and Energy Conservation for Section 1

HVAC Equipment
Eq ipment –Part
Part 2-
2 Agenda
DDC Control Applications
1. DDC Control Applications
2. DDC Networks and Architecture •Room
R E
Exhaust
h tB
Basic
i C
Control
t l
3. Communication Standards for DDC Controls •Air Handler Controls
•Constant volume-single zone
4. Vendor Examples of DDC Software Programming
and Operator Interfacing
g •Multi-zone
•Dual
D ld ductt
5. Understanding the Sequence of Operations •Variable air volume- VAV
6 System Maintenance and Service of DDC Controls
6. •Heating Systems with OSA Reset
7. Using DDC Controls to Save Energy • Energy Management Techniques for
Various AHU Fan Systems
2-3 2-4
DDC Application for a Room Single Zone Air Handler
Exhaust Control System Control Basics
•Controls temperature of similar zones

•Can utilize economizer
economizer, heating coils
coils, cooling coils
•Efficiency is increased based on zone requirements
PNWD-SA-8834 PNWD-SA-8834 Courtesy Honeywell Controls
2-5 2-6
Single Zone AHU Control Multi-Zone AHUs

Application with DDC Controller
• Air is blown over coils at the air handler in parallel

• Each zone thermostat controls a pair of interconnected dampers
which mix the air
• Efficiency increases when discharge air temperatures is reset
on zone requirements
• Reset hot and cold deck temperatures based on temperature
Courtesy LAMA Books sensor signals from the zones Courtesy Northwest Energy Efficiency Council
2-7 2-8
Dual Ducted System Variable Air Volume With Reheat
• Similar to multi-zone AHU,, except

p air is mixed in the zone
• Temperature blended hot/cold air • VAV systems vary the air supplied to each zone depending on the
load, saving fan energy.
• Mixing box near each zone
• VAV systems typically use cooling only air handlers.
• Damper linkages must be adjusted
• Volume of air delivered is varied using inlet dampers or electronic
• Efficiency based on temperature signals from zones speed controls based on supply duct static pressure setpoint.
2-9 2-10
Energy Management Techniques Many Factory Built-Up AHUs

Various AHU Fan Systems Are Variable Air Volume (VAV) with DDC Controls
•Single Zone/Constant Volume Systems
• Reset discharge air temperatures and mixed air temps based on zone
requirements.
•Multi-Zone and Dual Duct Systems
• Reset hot and cold deck temps
p based on zone loads & temperatures.
p
•Variable Air Volume (VAV)
• Use electronic VSD at the fan motor; supply and return fans should
track together. Use PI or PID to create fan stability.
•General Energy Saving Techniques for AHUs
• Operate zones based on load and occupancy needs.
• Set start and stop times to anticipate increasing and declining loads
loads,
based on inside and outside temperatures.
• Schedule the static pressure setpoint to drop after normal occupancy
hours, or during low load conditions.
• Disable the mechanical cooling coil and pumps when outside air
temperatures drop below 60 deg F. Source http://www.mmtmagazine.org/page/indexa916.html?id=44
2-11 2-12
Typical Controls on Factory AHUs Typical Controls on Factory AHUs
Example of Schematic for Alerton Controls Example of Schematic for Alerton Controls
Actuator Actuator
Sensors Sensors
Controller Controller
2-13 2-14
Throttling VAV Terminal Units Throttling VAV Terminal Unit
•Damper inlet controls supply air between

a min/max flow rate
•Includes a reheat coil and control valve
•Provide air to appropriate zones
•Min
Min setpoint pro
provides
ides eno
enough
gh fresh air
Components within the VAV box include:

• Room Thermostat or Sensor
• Velocity
V l it S Sensor
• Controller
Courtesy Nailor Industries

• Damper Actuator
2-15 2-16
Fan Powered VAV Terminal Unit Example of DDC Boiler
Heating Controls Schematic
• Fan provides constant volume

• Intermittent fan units
• Supply damper modulates min and max
• Reheat coil added to maintain min temp
• Fan runs as needed to maintain temperature
2-17 2-18
Boiler Control With OSA Reset Converter Control With Reset
Courtesy TAC Controls/Schneider Electric Courtesy Northwest Energy Efficiency Council

2-19 2-20
Reverse Reset
Air Handler Discharge
g Air Just as the term “action”
action is defined as reverse and direct,
direct
Heating Coil Control With Reset “reset” is also defined as reverse and direct. The hot water
reset, in this example is for reverse reset.
Reverse Reset Schedule
Courtesy Northwest Energy Efficiency Council Courtesy TAC Controls/Schneider Electric

2-21 2-22
Direct Reset Exercise

With direct reset, as the signal for
f the secondary input Identify the component location
increases, the setpoint increases. Direct reset is less 1. Zone Reheat Coil
common than reverse reset. An example p of direct reset is an 2. Static Pressure Controller
application called “summer compensation”, shown below. 3. Exhaust Air
4. Outdoor Air Intake
5 Preheat Coil
5.
6. Cooling Coil
7. Inlet Vanes or VSD
Summer Compensation
R
Reset
tSSchedule
h d l

2-23 2-24
Exercise Exercise-Identify
Exercise Identify the AHU Components
C
Converter
t CControl
t l With R
Resett Schedule
S h d l
1. Which is the primary sensor?

Hot Water Supply (HWS) or Outside Air Temperature (OAT)
2. What type of reset is this?
Di t R
Direct Resett or RReverse R
Resett
3. What action is needed at the controller?
Direct Action or Reverse Action Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric
2-25 2-26
Exercise In the illustration of this air handling Section 2

system,
t draw
d in
i th
the components t that
th t are missing
i i ffrom DDC N
Networks
t k and
dAArchitecture
hit t
the diagram using the items in the list.
Large Systems
Courtesy Northwest Energy Efficiency Council Courtesy DDC-Online Org

2-27 2-28
DDC Networks and Architecture DDC Networks and Architecture
LAN Configurations
C fi ti LAN Configurations
C fi ti
Courtesy DDC-Online Org Courtesy DDC-Online Org

2-29 2-30
Modern DDC Controls Have

Four Level Architecture Four Level Architecture
Level One “Sensors”
Courtesy Alerton Controls Courtesy Alerton Controls

2-31 2-32
Four Level Architecture
Four Level Architecture L l 3 “Integration”
Level “I t ti ”
Level Two “Field Controllers”
Courtesy Alerton Controls Courtesy Alerton Controls

2-33 2-34
Four Level Architecture Section 3

Level 4 “Management” Communication Standards
Software Integration
(TCP/IP BACnet
(TCP/IP, BACnet, LON)
Automation systems
y allow communication
with multiple vendors including:
• HVAC equipment
• Fire alarm, security
• Lighting,
Lighting fan units
• PLCs (programmable logic controllers)
• Boilers and chillers
Courtesy Alerton Controls
2-35 2-36
Interoperability
p y and Open
p Systems
y BACnet Software Standard Protocol
•BACnet, was developed by ASHRAE
Proprietary Systems vs
vs. Open Systems
•True, Non-proprietary, Open Protocol
Terms
•Industry Standardized
• Interoperability
p y
•Multiple
M lti l VVendor
d C Controllers
t ll
• Connectivity
• Interchangeability
Courtesy York/Johnson Controls

2-37 2-38
BACNet Gateways BACnet Connectivity

y
Courtesy DDC-Online Org

2-39 2-40
Third Party Interface LonWorks Platform and LONTalk
(Open Protocol) by a Proprietary
Manufacturer-Echelon
Refrigeration VSD’s
VSD s
Lighting
Unitary Controls
Power HVAC VAV OEM Access

PLC Equipment Control TAC Factory
Metering Lon Board and
Lon Talk
Neuron Chip
by Echelon
Courtesy DDC-Online Org
2-41 2-42
Exercise Exercise
Identify the Components of the Large Identify which DDC LAN Network is Polling and
System DDC Network, Fill in the Blanks which is a Controller LAN Network
2-43 2-44
Section 4 Typical Controls on Factory AHU Example
V d Examples
Vendor E l off S
Software
ft of Economizer Program for Alerton Controls
Programming and Graphical Interface Strategies Controller
Sensors
•Alerton Controls
•Siemens Building Technologies
•AutomatedLogic
Actuator

2-45 2-46
Typical Controls on Factory AHU Typical Controls on Factory AHU

Example of Economizer Program Example of Program
Components for Alerton DDC Process 'Energy\100KW' "Rm100 Energy" '\NCM-22'
PERIOD 00:01:00
Controller Exempt All
Shared SF1DAT!,RmTemp100!,Rm100VentKW!,RM100ClgKW!,Rm100HtgKW!,ClgCmd!(1),HtgCmd!(1)
Sensors PRIORITY 4
Rem inputs
CFM! = 'Rm-100\CS-Obj\AD_3'
CFMSetPt!='Rm-100\CS-Obj\AO_3'
HtgCmd! = 'Rm-100\CS-Obj\AO_1'
MinCFM! = 'Rm-100\CS-Obj\SP_8' :Rem MinCFM Cooling
MaxCFM! = 'Rm-100\CS-Obj\SP_7' :Rem MaxCFM Cooling
CoilKW! = 4.3
ClgCmd! = Span(CFMSetPt!,MinCFM!,MaxCFM!,0,100)
If (HtgCmd! < 1) and (ClgCmd! > 1) then

ClgKW! = 1.08 * abs(RmTemp100! - SF1DAT!) * (CFM! - MinCFM!) / 3412
VentKW! = 1.08 * abs(RmTemp100! - SF1DAT!) * MinCFM! / 3412
HtgKw! = 0.0
HtgCmd(1) = 0.0
ClgCmd!(1) = ClgCmd!
Actuator ModeA! = 2
……..

2-47 2-48
Typical Controls AHUs-Example Section 5
of AutomatedLogic Graphics Display for Understanding the Sequence of
Central AHU Controls Operations for DDC Controls
The sequence of operation explains:
“How the System is Designed to Operate” while
linking g the Operation
p with the Control Drawing”
g
It will include:
• Unit startup and shutdown
• Supply
S l ffan static
t ti pressure control
t l
• Cooling cycle and economizer operation
• Heating cycle
• Safety and limits
2-49 2-50
The Control Drawing is the Field Examples-Sequence of Operations

Picture for the Sequence of Operation for Unit and Fan Run and Shutdown
Unit Run Conditions:
• The initial duct static pressure setpoint shall be 0
0.5
5 in
in.
H2O
Supply Fan:
• The supply fan shall run anytime the unit is programmed or
commanded to run, unless shutdown on safety resason. To
prevent short cycling, the supply fan shall have a user
definable minimum runtime.
AHU Optimal Start:
• The
Th unitit shall
h ll start
t t prior
i tto scheduled
h d l d occupancy b based d on
the time necessary for the zones to reach their occupied
setpoints.
p The start time shall automatically
y adjust
j
based on changes in outside air temperature and zone
PNWD-SA-8834
2-51
temperatures.
PNWD-SA-8834
2-52
Examples-Sequence of Operations Examples-Sequence of Operations
for Supply Fan Static Pressure Control for the Cooling Cycle
Supply Air Duct Static Pressure Control: Cooling Stage Control:
• The
Th controller
t ll shall
h ll measure dductt static
t ti pressure and d •The controller shall measure the supply air temperature
modulate the supply fan VFD speed to maintain a duct and stage the DX cooling to maintain its cooling setpoint. To
static p
pressure setpoint.
p The speed
p shall not drop
p below prevent short cycling, the stage shall have a user definable
30% (adj.). (adj.) minimum runtime and differential setpoint.
Setpoint Control The cooling shall be enabled whenever:
• The static pressure setpoint shall be reset based on zone •Outside
Outside air temperature is greater than 60
60°F
F (adj.), AND
cooling requirements. The initial duct static pressure the economizer is closed to a minimum, AND the supply fan
setpoint shall be 0.5 in. H2O (adj.). status is on, AND the heating is not active.
• As cooling demand increases, the setpoint shall
incrementally reset up to a maximum of 0.75 in. H2O (adj.).
• As cooling demand decreases
decreases, the setpoint shall
incrementally reset down to a minimum of 0.25 in.
H2O (adj.) .
PNWD-SA-8834
2-53
PNWD-SA-8834
2-54
Examples-Sequence of Operations Examples-Sequence of Operations

for the Economizer Operation for the Heating Cycle
Economizer: Electric Heating Stage:
• The controller shall measure the mixed air temperature
p and • The controller shall measure the supply air temperature
modulate the economizer dampers in sequence to and stage the heating to maintain its heating setpoint. To
maintain a setpoint 2°F (adj.) less than the supply air prevent short cycling, the stage shall have a user definable
temperature setpoint.
setpoint The outside air dampers shall (adj.) minimum runtime.
maintain a minimum adjustable position of 10% (adj.) open The heating shall be enabled whenever:
whenever occupied. • Outside air temperature is less than 65°F
65 F (adj.), AND the
The economizer shall be enabled whenever: supply fan status is on, AND the cooling (if present) is not
• Outside air temperature is less than 65°F (adj.), AND the active.
outside air temperature is less than the return air Th h
The heating
ti stage
t shall
h ll run ffor ffreeze protection
t ti whenever:
h
temperature, AND the supply fan status is on. • Supply air temperature drops from 40°F to 35°F (adj.),
The economizer shall close to minimum (or close) whenever: pp y fan status is on.
AND the supply
• Mixed air temperature drops from 40°F to 35°F (adj.), OR
on fully close on loss of supply fan status or shutdown.
2-55 2-56
Exercise Section 6
Fill in the blanks or circle T or F, as needed to the
System Maintenance & Service of HVAC/DDC Controls
following questions:
and Associated Equipment
1.) The supply fan speed shall not drop below _____. •Fix
Fix Obvious Problems
2.) The initial duct static pressure setpoint shall be ____H2O . •Minimizing Nuisance Alarms
Trending and Recording
•Trending
3.) The outside air dampers will go to a minimum setting
whenever the outside air temperature is greater
•Setpoint vs. Control Point
than __°F
F and the fan is ________________. •Monitoring Graphics
•Calibrating Pneumatics
4.) T F The heating shall be enabled whenever the
outside air temperature is less than 55°F. •Air Compressor Checkout
5.) T F The cooling shall be enabled whenever the •Routine Inspection on VAV Boxes and AHU Coils
outside
outs de air
a tetemperature
pe atu e is
sggreater
eate tthan
a 60
60°F.
•Calibrating
C lib ti DDC P Panels
l
PNWD-SA-8834
2-57
•Loop Tuning
PNWD-SA-8834
2-58
Fix Obvious Problems Fix Obvious Problems

Outside Air Intake-Is
Intake Is this a Problem? Is the Damper Operator a Problem?
Notice the
condition of the Notice the
outdoor air intake
screens disconnected linkage
2-59 2-60
Minimizing Nuisance Alarms Trending and Recording
Setpoint vs.
vs Control Point
• Set alarms as low or as high as possible
• For
F example, l ththe alarms
l ffor a ttypical
i l room • Use the DDC computer functions for accuracy
temperature would be set at 78 F for a high
o when making measurements.
and 65oF for a low alarm • Plot out the DDC control panel and setpoint
• Daily repeat alarms should be repaired, not just concurrently to display actual working condition
acknowledged
g each day. y problems.
• Trend alarm points to better track actual • Trend
T d temperatures
t t andd analog
l sensors on
conditions time, not change of value (COV). Trending on
• Re-commission your building annually if alarms COV is only needed on binary devices
devices.
or out-of-control conditions consistently occur.
2-61 2-62
Monitoring Graphics
C lib ti
Calibrating Pneumatics
P ti
• Verify actual spring range of the controlled

• Monitor dynamic, real world displays, not static device for calibration
graphics • Cycle controller within spring range
• Look for normal and alarm conditions
• Compare setpoint to control point • Control point equals setpoint output during
• Review discharge air temperature compared to calibration
zone demands
d d • Pressure
P equalsl middle
iddl off spring
i range
• Reset temperatures based on zone requirements Courtesy TAC Controls/Schneider Electric
2-63 2-64
Routine Inspection Tips for VAV
Air Compressor
p Checkout Boxes and Associated Controls
Inspect the following parts routinely:
Check the Check the

• Listen to compressor Check the air flow
control
damper
fan
operation
• Check runtime length sensor reading
compared to a
for open-
closed
calibrated instrument Check the
• Check tank for water operation
control
valve for
• Check for oil in the water reheat
operation
• p
Inspect and replace
p all filters as needed
• Check output pressures at controllers
Ch
Change air
i filt
filter on
heating coil as needed
(when used)
2-65 2-66
Routine Inspection Tips for Heating Calibrating DDC Panels and

and Cooling Coils on AHU Units Control Loops
• Inspect the following parts routinely: • Use factory specs for power supply
• Upgrade motherboards within DDC
controllers as required to maintain
factoryy support
pp
• Use loop tuning software to adjust
software control loops under average
loads.
• Adjust one gain at a time
Check the economizer
dampers are modulating
Check the heating coil
• Seasonal loop calibration may needed
properly by commanding Check the cooling coil
to 0% and 100%, verify a valve by commanding to
valve by commanding to • Calibrate transmitters, transducers
0% and 100%, verify a
drop and raise in
temperatures as
0% and 100%, verify
drop and raise in
ya
drop and raise in etc against known sources per
etc.,
temperatures
compared to OSA and temperatures manufacturer specifications
RA temperatures. Courtesy Alerton Controls
2-67 2-68
Section 7
Using DDC Controls to Save Energy Using DDC Controls to Save Energy
Standard Economizers with Dry Bulb Control with Enthalpy Optimization
Airside Economizer: “A A duct
duct-
and-damper arrangement and
automatic control system
that, together, allow a cooling
system to supply outdoor air
to reduce or eliminate the
need for mechanical cooling
during mild or cold weather.”

2-69 2-70
Using DDC Controls to Save Energy Using DDC Controls to Save Energy
Electric Demand Limiting Time-Programmed Controls

2-71 2-72
Using DDC Controls to Save Energy Using
g DDC Controls to Save Energy
gy
Optimum Start/Stop Getting Back to the Basics
• Are the Pneumatic and DDC Control Systems

calibrated?
• Heating and Cooling Simultaneously?
• Sensing Correct Medium Locations?
• Optimum Setpoints
• Sensitivity Adjustments
• System Integration
• Scheduled Preventive Maintenance is a MUST!

2-73 2-74
Exercise Exercise
Fill in the blanks as needed to the following questions 1.)) T F Air is blown over coils at the air handler in p
parallel
2.) T F On a VAV fan system, the volume of air delivered
1.) To help minimize alarms on the DDC system, set alarms as is varied using inlet dampers or electronic speed
________ or as ________ as possible controls based on return duct static pressure setpoint.
3.) T F On a boiler control with outside air reset, the controller
automatically changes the supply water temperature set
2.) Trend temperatures and analog sensors on _________,
point based on the actual outside air temperature
temperature.
not ___________ of _________. Trending on ________ 4.) T F VAV terminal box units utilize a damper inlet that
is only needed on binary devices. controls supply air between a 0% closed and a
maximum flow rate and include a reheat coil and control
3.) Upgrade motherboards within DDC controllers as valve.
____________ to maintain ___________ support. 5.) T F Airside economizers simply utilize air source energy from
inside the building to cool the building or to supplement
4.) Calibrate transmitters, transducers etc., against the mechanical cooling system.
___________sources as per _____________specifications. 6.) T F The optimum start program computes the optimum time to
start the heating or cooling equipment so that at the precise
beginning of occupied time, the zone is at the desired
PNWD-SA-8834
2-75
temperature.
PNWD-SA-8834
2-76

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Automatic and DDC

Control Fundamentals Disclaimer

DDC Controls and Energy Conservation for Part 1

Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric

An example of a sensor is shown here. While it may

Pneumatic Sensors/Transmitters Electronic Sensors Include:

• Pneumatic controls sensors or transmitters • Resistance sensors are resistance temperature

• When 1000 ohms is measured across the Balco element, the

Controllers Can Include: Controllers basic principles

Electronic Controls Courtesy Johnson, Honeywell, and Alerton Controls

Courtesy Honeywell Controls Courtesy Northwest Energy Efficiency Council

Controller Action-Direct or Reverse

Courtesy DDC Online Org Courtesy Honeywell Controls

• This relationship between the input to a controller

Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric

Controller Reverse Action

Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric

– two-way Control Valves

The Present Control Systems

Courtesy Flow Control Valves

Parallel Blade Opposed Blade

Economizer Damper Actuators Parallel Blade Damper Characteristics

Direct Connect Actuator Damper Connected to Actuator

Courtesy T.A. & Co.

Electronic Variable DDC control systems have variable

•Vary frequency of motor to control speed • Cooling

Courtesy TAC Controls/Schneider Electric

Review of the Key

Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric

Review of the Key Control

Courtesy TAC Controls/Schneider Electric _________________ _________________ Courtesy Belimo

Courtesy DDC Online Org

Closed vs. Open Loop Control

Courtesy DDC Online Org Courtesy Northwest Energy Efficiency Council

Courtesy TAC Controls/Schneider Electric

Control Point and Offset Throttling

Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric

Courtesy PECI Courtesy Northwest Energy Efficiency Council

Two Position control action chart (heating action shown)

Courtesy Northwest Energy Efficiency Council

Proportional Control Action

Proportional Plus Integral (PI) Control Action

Courtesy Northwest Energy Efficiency Council

Review of Control Cycles Review of Control Cycles

Courtesy Northwest Energy Efficiency Council Courtesy TAC Controls/Schneider Electric

Pneumatic Controls Include: Pneumatic Control of Heating

Basic Electric Control

Courtesy LAMA Books Courtesy Honeywell Controls

Courtesy Honeywell Controls

Example of Electronic Control for

Courtesy Honeywell Controls

Smoke alarms Control of two

Temperature Room duct,

Humidities-Room, duct, OSA Motor speed control – VSDs

kWh power, volts, and amps Courtesy DDC Online Org.

DDC Control System DDC Control System

Courtesy Honeywell Controls

Courtesy DDC Online Org. Courtesy DDC Online Org.

DDC Control System DDC Control System

Courtesy Dwyer Instruments. Courtesy TAC Controls/Schneider Electric

Courtesy Belimo Courtesy Honeywell Controls.

Courtesy TAC Controls/Schneider Electric Courtesy TAC Controls/Schneider Electric

DDC Controls and Energy Conservation for Section 1

Courtesy TAC Controls/Schneider Electric _ _ Courtesy Belimo