If you’re interested in an HVAC career, now could be a great time to break into the field. According to Bureau of Labor Statistics (BLS) data, the job outlook for HVAC mechanics and installers is projected to grow by 9 percent between 2022 and 2032 alone. Meanwhile, HVAC professionals have the opportunity to work in a wide variety of settings, ranging from residential to commercial and even industrial.
An important part of working in HVAC is understanding the technical processes and equipment used on the job. And for industrial and commercial systems specifically, this includes a thorough understanding of programmable logic controllers (PLCs) and how to use them. So, what exactly is PLC in HVAC?
Discussing the Basics of HVAC Systems
Before we dive into the specifics of PLCs and their role in HVAC systems, let’s start with some basics.
Definition and Importance of HVAC in Modern Infrastructure
Specifically, “HVAC” refers to “heating, ventilation, and air conditioning.” HVAC technicians are the professionals responsible for servicing, maintaining, repairing, and installing these systems in buildings. In some cases, HVAC may also be referred to as “HVAC/R” when refrigeration is added to the title.
In modern infrastructure, HVAC is crucial because it allows inhabitants of a building to enjoy comfortable temperature control, even when the temperatures outside are extremely hot or cold. Not just homes, but commercial and industrial operations rely on properly functioning HVAC systems to keep things running smoothly.
Key Components of an HVAC System and Their Functions
While not all HVAC systems are exactly the same, many have the same essential parts and components, including:
- Thermostat– A wall-mounted unit used to control indoor temperature.
- Ductwork – In ducted HVAC systems, this refers to the series of ducts (usually made of sheet metal) that carry treated air to registers/vents throughout a building.
- Blower – The part that is responsible for circulating treated air throughout a building.
- Refrigerant lines – In cooling systems, this refers to the delivery system for refrigerant, which is required to cool air during the warmer months.
Introduction to PLC in HVAC Systems
Now that you have a better understanding of general HVAC, what is HVAC with PLC? Let’s explore this.
Understanding What a PLC (Programmable Logic Controller) Is
Specifically, a PLC refers to an industrial computer used in an HVAC system that is designed to operate in harsh environments, such as extreme temperatures and high winds. Within an HVAC system, a PLC can control any number of functions, ranging from air pressure and zoning to temperature and more.
The Role of PLCs in Enhancing HVAC System Efficiency
Rather than requiring separate controllers for different aspects of an HVAC system, a PLC makes it possible to monitor and control several aspects of a system from one centralized location. This improves diagnostic assessment and system management efficiency.
How PLCs Transform HVAC Operations
Compared to HVAC systems without PLCs, systems with PLCs can transform overall operations and building comfort in a number of ways.
Real-Time Monitoring and Control With PLCs
First, PLCs provide ongoing, real-time monitoring of various components of a system. At a quick glance, it is possible to control the following at any given time:
- Air temperature
- Air pressure
- Airflow
- Humidity levels
- Zoning systems
- Air quality levels
Many modern PLCs can also automate functions to maximize HVAC efficiency. For example, if sensors detect that a building is empty on the weekend, this information may be used to adjust the temperature within the building accordingly.
Advantages of Using PLCs for HVAC System Automation
Implementing PLCs into HVAC systems can not only improve system efficiency but are also extremely flexible and customizable to suit the client’s needs. For example, HVAC professionals and program PLCs to respond to certain inputs or to carry out different functions. This way, clients can get the most out of a PLC based on their specific needs.
From a safety aspect, PLCs can also be used to optimize safety by shutting off specific HVAC components as needed from one centralized location.
Implementing PLC Solutions in HVAC Systems
HVAC professionals who plan to work in industrial or commercial HVAC should understand the basic steps needed to implement PLC solutions into existing equipment.
Basic Steps for Integrating PLCs Into Existing HVAC Systems
First, the right PLC for the job must be chosen, as not all PLCs are compatible with all existing systems. From there, HVAC professionals need to be familiar with PLC software that allows them to create and implement the coding used to connect the PLC to the existing system and define its functions.
After PLC hardware and software are integrated, HVAC professionals should carefully monitor its performance and make changes as needed to optimize performance.
Case Studies: Successful PLC Implementation in HVAC Systems
There have been a number of examples of successful PLC implementation in HVAC systems. There is one particular example that comes to mind where a PLC was used to troubleshoot a recurring expansion valves error and poor AC performance on a container ship.
Challenges and Considerations in PLC-HVAC Integration
Working with HVAC PLCs professional can be a challenging yet rewarding process. Specifically, HVAC technicians need to be prepared to overcome common obstacles in integrating these systems together seamlessly.
Common Challenges in Merging PLCs with HVAC Systems
Perhaps the biggest challenge that HVAC professionals face when it comes to PLCs is simply choosing a PLC 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.
Overcoming Obstacles: Tips and Best Practices
The best way to avoid mismatches or incompatibilities with PLCs and HVAC systems is for HVAC professionals to become as educated as possible on PLCs, programming languages, and other specifications. Many HVAC professionals with PLC experience, for instance, have taken dedicated courses to learn about PLCs and how to integrate them.
The Future of HVAC Systems With PLC Technology
The HVAC industry is never static, with new innovations and technologies emerging rapidly. This also applies to PLC technology, which is becoming more efficient and user-friendly by the day.
Emerging Trends in HVAC Automation
With “smart” technology, HVAC systems with PLC are becoming easier to automate than ever. Precisely, this technology is making it possible to automate any number of PLC controls, including humidity and zoning, to maximize comfort and efficiency within a space.
Predictions for PLC and HVAC System Innovations
While only time will tell what the future holds for PLC and HVAC systems, it is likely that artificial intelligence (AI) and machine learning may also improve automation and control.
Learn More at FTC
PLC plays an important role in commercial and industrial HVAC, so it’s crucial for aspiring HVAC professionals to understand HVAC PLC applications and how to integrate it into existing systems.
Looking to learn more about PLC and other critical topics in HVAC? If so, then it may be time to pursue your HVAC/R with PLC diploma from Florida Technical College. In this career-focused program, you can expand your foundational knowledge on programmable logic controllers and other HVAC installation, maintenance, and service skills. Get in touch to learn more about this program or get started with your online application today.
These examples are intended to serve only as a general guide of possible employment opportunities. There are many factors that determine the job an individual may obtain and Florida Technical College cannot guarantee its graduates any particular job. Some positions may require license or other certifications. We encourage you to research the requirements for the particular position you desire.
