Modern companies often turn to upgraded technology to make their business operate more smoothly — but what about the hidden systems that keep things running? For many commercial establishments, a programmable logic controller (PLC) integrated into their heating, ventilation, and air conditioning (HVAC) system is a much-needed way to minimize energy costs, maintenance costs, and headaches associated with downtime.
Exploring the Basics of PLC in HVAC Efficiency
To begin, let’s discuss how PLCs work to improve HVAC efficiency in the first place.
Understanding the Role of PLC in Modern HVAC Systems
PLCs are designed to manage and control various processes. Essentially, a PLC refers to an industrial computer used in an HVAC system that is designed to operate in all kinds of environments. The data is processed in real time, making sure the HVAC runs at peak efficiency. Used to adjust different outputs (such as fans and dampers) in HVAC systems, a PLC can be used to monitor:
- Temperature
- Humidity levels
- Airflow
- Air pressure
- Air quality
The Evolution of HVAC Controls: From Manual to PLC
In the old days, HVAC systems needed manual controllers or a single thermostat. This lack of input data and automation makes it less efficient, and there is no room for input-based responses from the system.
Key Benefits of Implementing PLC-Based Control Solutions
Notable benefits associated with adding PLC-based controllers to different HVAC systems include:
Improving HVAC Energy Efficiency Through PLC Technology
With a PLC, you can introduce new technology like demand-controlled ventilation and variable speed drives into a new HVAC system. The addition of this technology helps save energy without compromising comfort.
How PLCs Contribute to Lower Operational Costs
With better control over the operation of an HVAC system, you can enhance the longevity of different systems. This is especially true in industrial settings, where reduced wear and tear on HVAC components can make a major difference when it comes to maintenance.
The Technical Edge: Integrating PLC With HVAC Systems
With that said, the above advantages rely on the ability to integrate a PLC into an existing or new HVAC system. This requires some technical know-how and a better understanding of PLC integration.
Simplifying HVAC System Management With Advanced PLC Integration
In general, the more advanced the PLC is, the simpler the HVAC management can be. Advanced PLC integration can automate a lot of processes, leaving less for the facilities team to manage. With a robust system, they might only need a single interface to monitor and adjust settings.
Case Studies: Successful PLC Implementations in HVAC
There exist numerous real-world applications of PLC integration into HVAC systems. In one case, an indoor farming company used high-tech PLC HVAC systems to precisely regulate temperature and humidity across different grow room zones. In another example, a PLC was used to troubleshoot a recurring expansion valves error and poor AC performance on a container ship.
Overcoming Challenges in HVAC Management With PLCs
It’s worth mentioning that managing an HVAC system can accompany additional challenges. Organizations may face system faults, general inefficiencies, and high maintenance costs related to running their HVAC. However, a smooth PLC integration can overcome many of these problems.
Identifying and Addressing Common HVAC System Faults Using PLCs
Perhaps the biggest challenge HVAC professionals face regarding PLCs is simply choosing one that will be most compatible with an existing HVAC system. Industrial and commercial HVAC systems can be especially complex, and not all PLCs are compatible with all equipment.
With this in mind, a PLC HVAC system can pick up on a fault through its continuous monitoring parameters. This allows a company to spot a deviation earlier — facilitating quicker maintenance and less downtime.
Enhancing HVAC System Reliability and Longevity With PLC Solutions
PLC integration will make sure the HVAC system runs at optimal operating conditions around the clock. This leads to better reliability and longevity of the HVAC, and the building will face fewer issues in the future.
Frequently Asked Questions:
As more establishments adopt PLC-based HVAC control solutions, let’s address some of the more commonly asked questions that concern the efficiency, compatibility, and implementation of PLC-based HVAC systems.
What makes PLC-based control solutions superior for HVAC efficiency?
HVAC PLCs offer real-time data that can help every HVAC system run with precision and efficiency. PLCs allow the system to change dynamically as the conditions change, resulting in optimal HVAC efficiency.
Can PLCs be integrated with all types of HVAC systems?
PLCs may be integrated into various HVAC configurations, whether they are centralized or decentralized. Generally speaking, PLCs can integrate with any type of existing or new HVAC system. This is why you see PLC-based HVAC systems used across industries and applications.
What are the initial steps to transition to a PLC-based HVAC control system?
The first key step is defining the control objectives and picking the right PLC hardware and software. From there, the team must plan the integration process and bring in the right talent to facilitate the upgrade. It invariably calls for a PLC expert with a deep understanding of HVAC technology.
How do PLC-based systems handle HVAC system fault detection?
Fault detection is a result of the continuous monitoring done through the PLC system. The PLC will come with different thresholds, and when one of the parameters goes below or above a threshold, the HVAC PLC can trigger an alarm that allows an operator to make a change. In other systems, the PLC has autonomy over the HVAC system and will adjust output settings to deal with system faults.
Are there any limitations to using PLCs in HVAC applications?
Using a PLC in HVAC applications comes with a few limitations. For one, there is an initial cost associated with investigation, implementation, and upgrading of the system. In addition, companies will need to source and pay for a PLC expert to handle the upgrade. There are additional size and operational confines that must be handled on a per-project basis. However, these limitations may pale in comparison to the long-term advantages of energy savings and system reliability.
Learn More About HVAC and PLC at FTC
Through the technical and practical knowledge unlocked in an HVAC/R with PLC diploma program, you can learn all about PLCs and how they can integrate into HVAC systems. At Florida Technical College (FTC), you will learn the skills required to make common PLC-based HVAC upgrades and pursue roles within construction firms plus both residential and commercial refrigeration and air conditioning companies.
This article presents a general overview of the field of HVAC/R with PLC, including job opportunities within that field; it does not describe the educational objectives or expected employment outcomes of a particular Florida Technical College program. Florida Technical College does not guarantee that students will obtain employment or any particular job. Some positions may require licensure or other certifications. We encourage you to research the requirements for the particular career you desire.
Sources
https://ftccollege.edu/program/diploma/hvac-r-with-plc-diploma-english/
https://csrc.nist.gov/glossary/term/programmable_logic_controller
