IKON Drive Boiler Heat Exchange IoT Solution
Author: IKON Drive Technical Support Department
The boiler heat exchange system, taking the bath center as an example, mainly includes: shower system, pool injection system, heat source system, geothermal system, sweat steaming system, etc. In terms of control, it can be subdivided into water tank control (high temperature water tank, constant temperature water tank, hot spring water tank, cold water water tank); frequency conversion pressure control: water pressure control, geothermal pressure, geothermal second-stage pressure (pressure control is mainly controlled by the controller PID, Real-time automatic adjustment), and control of liquid level, temperature, valve switch, etc.
In addition, friendly human-computer interaction is also required. The human-machine interface HMI needs to meet:
● There are flow charts, actual location installation diagrams, and schematic diagrams on the screen, which can display temperature, pressure, liquid level value, valve, motor switch status, etc. in real time. The entire system can be manually and automatically controlled, parameters can be changed, and alarm information can be displayed.
● The whole system can be monitored on the computer, and the actual temperature, pressure, liquid level value, valve, motor switch status, etc. can be displayed on the screen; the entire system can be manually and automatically controlled, parameters can be changed, and alarm information can be displayed.
● Remote computer and mobile APP can check the system status.
● Alarm information can be sent to the designated mobile phone number through the mobile phone module.
Figure 1 Partial scene diagram of the bathing center
1. The hardware configuration of the program
1. C7 touch screen: 7-inch TFT screen, 800×480 resolution, A8 CPU, 4G Flash, 512M RAM. support:
● Program download via serial port/U disk/SD card/Ethernet/Haiwei Cloud;
● Intelligent management, support cloud/mobile terminal access control, strong operability;
● Innovative A/B Key security mechanism, multi-language automatic translation, project overview interface;
● Integrated IKON Drive Cloud cloud service, built-in IKON Drive cloud engine; can remotely realize functions such as mobile phone APP, computer cloud website, SMS alarm and map positioning.
2. IKON Drive T series standard PLC, which can be extended to 7 modules, comes with one RS232, one RS485 port, 2 channels of 200K high-speed pulse input, 2 channels of 200K high-speed pulse output, the program is permanently saved, and the program capacity is 48K. Rich instructions, fully meet the needs of on-site logic control.
3. Q17 IKON Drive IPC Industrial Computer
● Linux system, 17-inch TFT screen, 1280×1024 resolution;
● Intel i3 processor, 4G DDR3, 32G SSD, 4*COM (1*RS485), 1*RJ-45 interface (1000MB), 4*USB, 1*VGA, 1*HDMI
● Optional WIFI, aluminum alloy shell, industrial ATX power supply.
2. Scheme Network Diagram
Figure 2 On-site PLC HMI electrical cabinet
3. Program introduction
The control system has a total of 6 cabinets, three PLC control systems, and the host has several modules. The specific PLC configuration is as follows:
Field control cabinet 1# configuration: T60S0R-e + H40XDR + S08AI + S08AI + S08AO
Field control cabinet 2# configuration: T48S0R-e + H24XDR + H40DI
Field control cabinet 3# configuration: T60S0R-e + H64XDR + H40DI
Figure 3 Assembling the on-site cabinet (the picture on the right is the control cabinet 1#)
Figure 4 Equipment site cabinet
Figure 5 On-site heating and heat exchange piping
4. Part of the program
● HMI part program
Figure 6 Boiler room monitoring screen
Figure 7 Boiler room operation screen
● PLC part program
Figure 8 TIME command realizes automatic timing switch
Figure 9 PID command pressure control
5. Successful cases
● Xi’an Fengcheng Bath Center
Figure 10 Mobile APP monitoring of Xi’an Fengcheng Bathing Center
● Shandong Pingyin Bathing Center
Figure 11 Mobile APP monitoring of Shandong Pingyin Bathing Center
● Qingdao Jimo Bath Center
Figure 12 Mobile APP monitoring of Qingdao Jimo Bathing Center
● Henan Jiaozuo Bath Center
Figure 13 Mobile APP monitoring of Henan Jiaozuo Bathing Center
6. Program summary
1. This solution needs to control the water pressure and temperature of the multi-channel pipelines on site. IKON Drive PLC can support 32 channels of PID + 32 channels of self-tuning APID + 32 channels of FTC, with many PID loops, good control effect, and real-time controllable on-site pressure. The special feature is APID self-tuning, which is convenient for temperature control on site, and self-tuning parameters saves debugging time for on-site engineers, and the control accuracy meets the requirements.
2. The Ethernet PLC is selected on site. The Ethernet PLC supports simultaneous access by multiple upper computers. At the same time, the Ethernet port can also be used as the master station to access other devices, which can be master and slave, which is convenient for debugging.
3. Through the IKON Drive touch screen, you can also remotely upload and download HMI programs, upgrade firmware, and export historical data records.
4. Through the IKON Drive touch screen, you can also remotely upload and download PLC programs, upgrade firmware, monitor and diagnose PLC information.
5. The on-site liquid level, pressure, and pump overload alarm information can be transmitted to the touch screen owner and the administrator’s mobile phone in time, and sent to the user in the form of APP message push. If the APP is not running in the background, it will also send the information that can be used to text messages to the user.