CONTROLLER FOR INDUSTRIAL MUSHROOM CULTIVATION

Transcription

1 AKS CONTROLLER FOR INDUSTRIAL MUSHROOM CULTIVATION VERSION Instruction Manual

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3 CONTENTS 1. PURPOSE SPECIFICATIONS SHORT DESCRIPTION Controller s Operation Controller s Design OPERATOR PANEL Screensaver Measurements Window Group Main Parameters Room Air Temperature Relative Humidity in the Growing Room Compost Temperature СО2 Level Control Window Group Water Coil Control Air Damper Control Inlet Fan Control Support Algorithms and Devices Used for Automatic Control Outside Air Damper and Inlet Fan Control Alarms Connecting and Disconnecting Temperature Probes Settings Window Group First Settings Window Second Settings Window Third Settings Window Event Log Main Menu AKS Setup Menu AKS Data Settings Menu Operator Panel Settings Menu Archiving Submenu Visualization Submenu Data Transfer with PC Submenu Date and Time Submenu Reset Submenu Network Configuration Submenu View Archive Submenu Login Submenu Help Submenu CONTROLLER OPERATION Measurements Room Air Temperature Measurement Relative Humidity Measurement Room Air Temperature Measurement CO2 Concentration Measurement Temperature Measurement in the Air Duct Climate Support Algorithms Compost Temperature Leveling Compost Temperature Support Air Temperature Support Relative Humidity Support CO2 Concentration Support Hot Water Coil Protect from Freezing Drying after Watering Processing Actuator Operation

4 6. ALARMS, CAUSES AND TROUBLESHOOTING Malfunction of Air Temperature Probes or Room Air Temperature is out of Range Malfunction of Compost Temperature Probes or Compost Temperature is out of Range Malfunction of Humidity Sensors or Humidity in the Room is out of Range Malfunction of CO2 Sensor or CO2 Level in the Room is out of Range Malfunction of Hot Water Valve or Pump, Malfunction of Cold Water Valve or Pump Malfunction of Inlet Fan or VFD Malfunction of Exhaust Fan Malfunction of Outside Air Damper Malfunction of Circulation Air Damper Malfunction of Humidifier Valve or Pump Risk of Hot Water Coil Freeze A Lack of Communication with Top or Bottom PCBs of the Master Controller SAFETY GETTING STARTED TERMIAL CONNECTIONS AND WIRING DIAGRAMS CONNECTION OF DEVICE NETWORK TO PC MARKING MAINTENANCE STORAGE TRANSPORTATION

5 This User s Manual is aimed at service staff to familiarize with the device, the principle of operation, construction and maintenance of AKS controller for industrial mushroom (Agaricus) cultivation (hereinafter AKS Controller). 1. PURPOSE 1.1 AKS Controller is designed to control air and compost temperature, relative humidity (RH), CO2 content in a growing room and air temperature in several points of the duct. Temperature is measured by resistance temperature detector (RTD) probes. If necessary, any measurement channel can be disabled. To improve the accuracy of temperature measurement, the specific algorithms of data processing are introduced in AKS controller. Relative humidity is measured by dry and wet bulbs called psychrometer which calculates the difference in readings between two thermometers. 1.2 Process scheme of the growing room is shown in Fig Compost temperature probe 5 Psychrometer (dry and wet bulbs) 6 Room air temperature probe 7 CO2-content sensor 8 Inlet air temperature probe 9 Cool air temperature probe 10 Mixed air temperature probe 11 Outside temperature probe 12 Return hot water temperature probe 13 Return cold water temperature probe 14 Outside air damper 15 Circulation air damper 16 Chilled water valve 17 Chilled water circulation pump 18 Hot water valve 19 Hot water circulation pump 20 Inlet fan 21 Inlet fan VFD 22 Humidifier valve 23 Humidifier pump 24 Exhaust fan 25 Pressure valve Fig.1.1 Process scheme of the growing room 5

6 1.3 AKS Controller supports seven growing phases: - Spawn run 1. Keeping the optimum compost temperature for the spawn growth. - Spawn run 2. Keeping the optimum compost temperature for the spawn growth into the casing soil. - Spawn run 3. Keeping the optimum compost temperature for the spawn recovery after the casing soil has been ruffled. - Cool down pinning. Changing the climate parameters in order to slow the spawn growth and stimulate pinheading. - Pinheading. Keeping the stable climate parameters in order to form pinheads. - Harvesting. Keeping the stable climate parameters for mushroom growth into harvestable mushrooms. - Cook out. Smooth increase in temperature in order to prepare the room and compost for steaming. The technological parameters and phase control settings are stored in non-volatile memory which retains information after power off. 1.4 AKS Controller supports three accessory operating modes: - Leveling. Increase in frequency of inlet fan speed in order to increase temperature compost leveling. Leveling mode is turned on by toggling the switch placed on AKS controller and used only for Spawn run 1 and Spawn run 2 growing phases. The mode is turned off either by toggling the switch or automatically when compost temperature is leveled. - Processing. Disabling air handling unit during special technological operations (casing, ruffling, disinfection, etc.). The mode is turned on and off by toggling the switch placed on AKS controller. - Drying after Watering. Automatic dewatering of mushroom caps according to the algorithm specified by a technologist (used only for the Pinheading and Harvesting phases). The mode is turned on by toggling the switch placed on AKS controller and off either by toggling the switch or automatically at the end of the specified period. 1.5 AKS Controller constantly checks that probes and actuators are functioning properly. Failures and climate problems are displayed on the operator panel. Also the external indicator alarms such as Climate Problem, Faulty Actuator and Risk of Frost are generated. 1.6 AKS Controller generates and stores the event and alarm log in the non-volatile memory. The log is available for viewing on the operator panel or remotely from PC. 1.7 AKS Controller generates and stores the sensor readings and actuator archive state in the non-volatile memory. Archive is available for viewing on the operator panel or remotely from PC. 1.8 AKS Controller provides data exchange with PC via RS485, T-Bus communications protocol. All operations are performed either on the operator panel keyboard or remotely from PC. The software may be supplied separately from AKS controller. The number of AKS controllers connected to a single link is maximum The controller is designed to use in the following ambient climate: Temperature +5 to +40 С Atmospheric pressure 86 to 107 kpa Relative humidity (non-condensing) 30 to 80% 6

7 2. SPECIFICATIONS 2.1 Main specifications of AKS Controller are shown in Table 2.1. Table 2.1 Specifications of AKS Controller Characteristic Value Nominal Voltage, V AC 24 Tolerance of Supply Voltage, % Power Consumption, W Max 6 Number of Temperature Inputs 16 Types of Temperature Sensors RTD 1000 W100=1,3850 Temperature Range, С Device accuracy class for temperature inputs (excluding sensor accuracy), % 0,1 Number of Analog Inputs 8 Types of Analog Inputs See Table 2.2. Device Accuracy Class for Analog Inputs, % 0.2 Number of Analog Outputs 8 Types of Analog Outputs See Table 2.3 Number of Dry Contact Inputs 20 Type of Dry Contact Inputs 24V 5mA DC Number of Output Relays 11 Type of Output Relays 2А 22В Number of Impulse Outputs 8 Type of Impulse Outputs 12V 10mА DC Protection Class of Operator Panel IP54 Dimensions of Operator Panel, mm 96x96x50 Protection Class of Master Controller IP40 Dimensions of Master Controller, mm 155x90x60 Weight, kg Max 0.7 Table 2.2 Types of Analog Inputs Code Output Voltage/Current Measuring Range of Control Parameter V % V % V % ma Set by the user in accordance with specifications of CO2 and ma humidity sensors ma Table 2.3 Types of Analog Outputs Types of Analog Output Code Value V Voltage Outputs V V 7

8 2.2. The functional purpose of inputs and outputs. Table 2.4 Functional Purpose of Measuring Inputs Name Input No. Input Contact Purpose Type Connectors Т1 Input 1 #10 RTD Compost Temperature 1 Х1:2,3 Т2 Input 2 #10 RTD Compost Temperature 2 Х1:4,5 Т3 Input 3 #10 RTD Compost Temperature 3 Х1:6,7 Т4 Input 4 #10 RTD Compost Temperature 4 Х1:8,9 Т5 Input 5 #10 RTD Reserved Х2:1,2 Т6 Input 6 #10 RTD Reserved Х2:3,4 Т7 Input 7 #10 RTD Outside Air Temperature Х2:5,6 Т8 Input 8 #10 RTD Mixed Air Temperature Х2:7,8 Т9 Input 1 #11 RTD Dry Bulb Temperature Х11:2,3 Т10 Input 2 #11 RTD Wet Bulb Temperature Х11:4,5 Т11 Input 3 #11 RTD Room Air Temperature Х11:6,7 Т12 Input 4 #11 RTD Cool Air Temperature Х11:8,9 Т13 Input 5 #11 RTD Return Hot Water Temperature Х12:1,2 Т14 Input 6 #11 RTD Return Cold Water Temperature Х12:3,4 Т15 Input 7 #11 RTD Inlet Air Temperature Х12:5,6 Т16 Input 8 #11 RTD Reserved Х12:7,8 U1 Input 9 #10 Voltage Outside Air Damper Х6:4,5 U2 Input 10 #10 Voltage Circulation Air damper Х6:6,5 I3 Input 11 #10 Current CO2-content Х6:7,8 I4 Input 12 #10 Current Reserved Х6:9,8 U5 Input 9 #11 Voltage Cold Water Valve Х9:4,3 U6 Input 10 #11 Voltage Hot Water Valve Х9:5,3 U7 Input 11 #11 Voltage Reserved Х9:6,3 U8 Input 12 #11 Voltage Inlet Fan Х9:7,3 Table 2.5 Functional Purpose of Dry Contact Inputs Name Input No. Purpose Contact Connectors DI 1 DC1 #10 Reserved Х4:2,1 DI 2 DC2 #10 Reserved Х4:3,1 DI 3 DC3 #10 Reserved Х4:4,1 DI 4 DC4 #10 Thermostat Signal from Hot Water Coil Х4:5,1 DI 5 DC5 #10 Processing Toggle Х4:6,1 DI 6 DC6 #10 Drying after Watering Toggle Х4:7,1 DI 7 DC7 #10 Leveling Signal Х4:8,1 DI 8 DC8 #10 Alarm Test Signal Х4:9,1 DI 9 DC1 #11 Cold Water Circulation Pump Х10:1 DI 10 DC2 #11 Hot Water Circulation Pump Х10:2 DI 11 DC3 #11 Power Supply Х10:3 DI 12 DC4 #11 Exhaust Fan Х10:4 DI 13 DC5 #11 Reserved Х10:5 DI 14 DC6 #11 Humidifier Circulation Pump DI 15 DC7 #11 Reserved DI 16 DC8 #11 Reserved DI 17 DC1 on the operator panel Measurement Display Mode Button DI 18 DC2 on the operator panel Control Display Mode Button DI 19 DC3 on the operator panel Settings Display Mode Button 8

9 DI 20 DC4 on the operator panel Event Log Display Mode Button Table 2.6 Functional Purpose of Analog Outputs Name Output No. Purpose Contact Connectors Y1 Output 1 #10 Control of Outside Air Damper Х5:7,8 Y2 Output 2 #10 Control of Circulation Air Damper Х5:9,8 Y3 Output 3 #10 Reserved Х6:1,2 Y4 Output 4 #10 Reserved Х6:3,2 Y5 Output 1 #11 Control of Cold Water Valve Х8:8,7 Y6 Output 2 #11 Control of Hot Water Valve Х8:9,7 Y7 Output 3 #11 Reserved Х9:1,3 Y8 Output 4 #11 Control of Inlet Fan Speed Х9:2,3 Table 2.7 Functional Purpose of Digital Outputs Name Output No. Output Contact Purpose Type Connectors DO 1 Output 1 #10 Relay CO2 shot Х5:1,2 DO 2 Output 2 #10 Relay Reserved Х5:3,2 DO 3 Output 3 #10 Relay Leveling Signal Х5:4,5 DO 4 Output 4 #10 Relay Reserved Х5:6,5 DO 5 Output 5 #10 Relay Light Signal ON/OFF Х3:1,2 DO 6 Output 6 #10 Relay Sound Signal ON/OFF Х3:3,2 DO 7 Output 7 #10 Relay Processing Signal Х3:4,5 DO 8 Output 8 #10 Relay Drying after Watering Signal Х3:6,5 DO 9 Output 1 #11 Voltage Cold Water Circulation Pump ON/OFF Х7:5; Х8:6 DO 10 Output 2 #11 Voltage Hot Water Circulation Pump ON/OFF Х7:6; Х8:6 DO 11 Output 3 #11 Voltage Inlet Fan ON/OFF DO 12 Output 4 #11 Voltage Exhaust Fan ON/OFF DO 13 Output 5 #11 Voltage Humidifier Valve ON/OFF Х8:2; Х8:6 DO 14 Output 6 #11 Voltage Reserved DO 15 Output 7 #11 Voltage Reserved DO 16 Output 8 #11 Voltage Reserved DO 17 Output 1 on the operator Relay Climate Problem Signal panel DO 18 Output 2 on the operator Relay Faulty Actuator Signal panel DO 19 Output 3 on the operator panel Relay Risk of Frost Signal 9

10 3. SHORT DESCRIPTION 3.1 Controller s Operation AKS Controller consists of the operator panel and the master controller connected by a digital link. The general functional diagram of AKS Controller is shown in Figure 3.1. Fig.3.1 Functional diagram of AKS Controller The operator panel includes a color TFT display, keyboard, real time clock, memory and digital interfaces for communication with PC and master controller. The operator panel also contains external buttons for setting display modes, as well as alarm indicator lamps: Climate Problem, Faulty Actuator and Risk of Frost The master controller has temperature (RTD) measuring inputs and analog voltage and current inputs. Besides, the master controller processes input signals of dry contacts and controls digital and analog outputs The control parameters are entered from the keyboard of the operator panel and stored in its memory. The processor of the operator panel calculates current set compost and air temperatures, relative humidity and CO2 level in a growing room and transmits them to the master controller. The processor also performs a comprehensive analysis of all climate parameters and, considering outside air and priorities specified by a technologist, it decides about optimal use of air handling unit. The master controller generates control signals to air handling unit based on the comparison of measured and specified climate parameters. For detailed description of the operator panel display modes, please, refer to Section 4. For detailed description of the control process, please, refer to Paragraph

11 3.2 Controller s Design The operator panel is made in plastic enclosure designed for use in the electrical panel board The master controller is mounted on DIN-rail The front side of the operator panel contains a graphical TFT display (Figure 3.2) and five control buttons. Fig.3.2 Front Panel The right side of the front panel is used to indicate faults and communication with PC. The purpose of LEDs on the operator panel is given in Table 3.1. Table 3.1 Purpose of LEDs on the Operator Panel Number of Indicator Symbol Indicator Color Functional Purpose 1 AT Red Air temperature probe fault or air temperature is out of range 2 CT Red Compost temperature probe fault or compost temperature is out of range 3 Rh Red RH sensor fault or RH is out of range 4 CO2 Red CO2 sensor fault or CO2 level is out of range 5 CE Red Cold water valve or pump fault 6 HE Red Hot water valve or pump fault 7 IF Red Inlet fan fault 8 EF Red Exhaust fan fault 9 OA Red Outside air damper fault 10 CA Red Circulation air damper fault 11 HM Red Humidifier fault 12 PS Red Power supply fault 13 Up Red Indication of fault data exchange between the operator panel and the top PCB of master controller 14 Dn Red Indication of fault data exchange between the operator panel and the bottom PCB of master controller 15 RS Green Communication with PC Terminal connectors for sensors, power supply, outputs and communication interfaces are placed on the back of the operator panel and on the master controller. 11

12 4. OPERATOR PANEL AKS is multifunctional controller with plenty of modes and settings. In order to simplify the work with AKS controller, information is organized in dialog windows. Five dialog windows are realized in the controller. They are: - Measurements; - Control; - Settings; - Event and Alarm Log; - Menu. The Measurements window group is activated by the external button connected to DC1 input on the operator panel (see Table 2.5, paragraph 2.2). The button is usually located on the front of the panel board and is marked as. The Control window group is activated by the external button connected to DC2 input on the operator panel (see Table 2.5, paragraph 2.2). The button is usually located on the front of the panel board and is marked as. The Settings window group is activated by the external button connected to DC3 input on the operator panel (see Table 2.5, paragraph 2.2). The button is usually located on the front of the panel board and is marked as. The Event and Alarm Log window is activated by the external button connected to DC4 input on the operator panel (see Table 2.5, paragraph 2.2). The button is usually located on the front of the panel board and is marked as. Press simultaneously two buttons & on the operator panel from any group of dialog windows to enter the menu. All windows of the groups Measurements, Control and Settings have the same structure. The results of measurements and calculations are displayed in the central part of the window. The values are also entered in the central part of the window. The Faulty symbol instead of current readings indicates the corresponding probe fault, the Off symbol disabled state. The right part of the window has a black background and is designed to show alarms and data exchange via RS485 (see Table 3.1, paragraph 3.2.4). The bottom part of the window is designed to show active buttons of the operator panel. Active buttons are displayed in green, the rest field is grey. The enter the menu. button is always active and closely resembles that from any window is possible to 4.1 Screensaver As soon as the power on, the screensaver is displayed. The bottom of the screen contains the controller s firmware version. Fig.4.1 Controller s Screensaver 12

13 The screensaver lasts for 30 seconds. During this time AKS Controller is preparing for operation. The indicator of loading is displayed. After that the controller automatically goes to the first page of the Measurements window group. 4.2 Measurements Window Group Main Parameters Fig.4.2 Main Indicators The top line shows the current cultivation phase and its current duration. The rest part of the screen displays main process parameters: - Тair Average air temperature in the growing room (see paragraph 5.1.1) and the readings of air temperature probes in the growing room. - Rh Relative humidity in the growing room (see paragraph 5.1.2). - Тcomp Average compost temperature (see paragraph 5.1.3) and the readings of compost temperature probes. - СО2 Current concentration of carbon dioxide in the growing room. Press to enter another phase (see paragraph 1.3). The window of the phase change will appear (see Fig.4.3). Fig. 4.3 Phase Change Pressing the buttons &, go to the Phase line and press button. The phase title is highlighted background. Pressing button, change the phase and click. To close the window, press buttons &, go to the Back line and press. Phase title in the upper part of the window will change and the duration of the phase starts counting from zero. 13

14 4.2.2 Room Air Temperature Fig.4.4 Room Air Temperature The window displays: - Тair Mathematically processed result of air temperature measurement in the growing room. Parentheses show the way by which the temperature is calculated: (average) Result of averaging the readings of two room air temperature probes. (min) The smallest reading of two room air temperature probes. (max) The highest reading of two room air temperature probes. (Тair1) Reading of the first room air temperature probe. (Тair2) Reading of the second room air temperature probe. The mathematically processed result of room air temperature measurement is displayed in red on the graph. - Тair.contr. Control air temperature (see paragraph 5.2.2), displayed in blue on the graph. - Тair.set.cur Current set room air temperature (see paragraph 5.2.3), displayed in black on the graph. - Тair.set.phase Room air temperature specified for the current cultivation phase (see paragraph 4.4.1). - Тair1 Reading of the first room air temperature probe. - Тair2 Reading of the second room air temperature probe. To change the method by which room air temperature is calculated, press window of calculating method change will appear (see Figure 4.5). button. The Fig. 4.5 Change of Calculating Method Pressing the buttons &, go to the Calculate by line and press button. The calculating method is highlighted background. Pressing button, change the phase and click. To close the window, press buttons &, go to the Back line and press. Method name in the upper part of the window will change and the room air temperature is calculated according to the selected method. 14

15 4.2.3 Relative Humidity in the Growing Room Fig.4.6 Relative Humidity in the Growing Room The window displays: - Rh.meas. Result of humidity measurement in the growing room, displayed in red on the graph. - Rh.set.cur. Current set air humidity in the growing room (see paragraph 5.2.4), displayed in blue on the graph. - Rh.set.phase Air humidity in the growing room specified for the current cultivation phase (see paragraph 4.4.1). - Тdry Dry bulb temperature. - Тwet Wet bulb temperaturer. - Тc.air Cool air temperature Compost Temperature Fig.4.7 Compost Temperature The window displays: - Тc - Mathematically processed result of compost temperature measurement in the growing room. Parentheses show the way by which the temperature is: (av.) Result of averaging the readings of six compost temperature probes considering the probes excluded by limit value (see paragraph 5.1.3). (min) The smallest reading of six compost temperature probes. (max) The highest reading of six compost temperature probes. (Тcomp1) Reading of the first compost temperature probe. 15

16 (Тcomp2) Reading of the second compost temperature probe. (Тcomp3) Reading of the third compost temperature probe. (Тcomp4) Reading of the fourth compost temperature probe. The mathematically processed result of compost temperature measurement is displayed in red on the graph. - Тc.set.cur. Current set compost temperature (see paragraph 5.2.2), displayed in blue on the graph. - Тc.set.ph. Compost temperature specified for the current cultivation phase. - 1., 2., 3., 4. Current readings of four compost temperature probes. - Limit Allowable variation of compost temperature used in calculating the average value (see paragraph 5.1.3). - Excl Numbers of excluded probes (see paragraph 5.1.3). The measured average and current set compost temperatures are displayed on the graph. To change the allowable limit and the method by which the compost temperature is calculated, press button. The next window will appear (see Figure 4.8). Fig.4.8 Change of Calculating Method and Allowable Limit Pressing the buttons &, go to the Calculate by line and press button. The calculating method is highlighted background. Pressing button, change the phase and click. Pressing the buttons &, go the Limit line and press button. The limit value is highlighted background. Pressing,,,, change the limit and press. To close the window, press buttons &, go to the Back line and press. Method name and limit value in the upper part of the window will change and the compost temperature in the growing room is calculated according to selected method and limit value СО2 Level Fig.4.9 CO2 Level 16

17 The window displays: - СО2meas. Current measured CO2 result. - СО2set.cur. Current set CO2 level (see paragraph 5.2.5). - СО2set.phase CO2 level specified for the current cultivation phase. Additionally displayed: - Тinlet Inlet air temperature. - Тmix Mixed air temperature. Measured and set levels of СО2 are displayed on the graph. 4.3 Control Window Group Water Coil Control Fig.4.10 Water Coil Control The window displays: - Water Coil Current purpose of water coil (see paragraph 5.3): Heating Air heating. Cooling Air cooling. Heat,dry Simultaneous air heating and drying. Cool,dry Simultaneous air cooling and drying. - HE Measured and set position of hot water valve; control mode of hot water valve (manual/automatic); measured and set state of hot water pump; control mode of hot water circulation pump (manual/automatic). - Hum Measured and set state of humidifier; control mode of humidifier (manual/automatic). - Thw.back Return hot water temperature; - CCU State of four compressors of CCU (ON/OFF); - Tbccu Back coolant temperature. Measured position of water valves is displayed on the graph at the bottom of the screen. In this window, using the keyboard of the operator panel, a user can change the control mode of coil (i.e. hot water valve and four CCUs), hot water pump and humidifier, as well as change the state of actuators in the manual control mode. 17

18 4.3.2 Air Damper Control Fig.4.11 Air Damper Control The window displays: - Outside Air Current purpose of outside air damper (see paragraph 5.3): CO2 CO2 decrease. Cool Air cooling. CO2,cool Simultaneous CO2 decrease and air cooling. Dry Air drying. CO2, dry Simultaneous CO2 decrease and air drying. Cool,dry Simultaneous air cooling and drying. CO2,cool,dry Simultaneous CO2 decrease, air cooling and drying. - OA Measured and set position of outside air damper; air damper control mode (manual/automatic). - CA Measured and set position of circulation air damper. - Тoutside Outside air temperature. Measured position of outside air damper is displayed on the graph. In this window, using the keyboard of the operator panel, a user can change the control mode of air dampers, as well as change their state in manual control mode Inlet Fan Control The window displays: Fig.4.12 Inlet Fan Control 18

19 - Inlet Fan Current purpose of inlet fan (see paragraph 5.3): Lvl Compost leveling. CO2 CO2 decrease. Lvl,CO2 Simultaneous compost leveling and CO2 decrease. Cool Air cooling. Lvl,cool Simultaneous compost leveling and air cooling. CO2,cool Simultaneous CO2 decrease and air cooling. Lvl,CO2,cool Simultaneous compost leveling, CO2 decrease and air cooling. Dry Air drying. Lvl,dry Simultaneous compost leveling and air drying. CO2,dry Simultaneous CO2 decrease and air drying. Lvl,CO2,dry Simultaneous compost leveling, CO2 decrease and air drying. Cool,dry Simultaneous air cooling and drying. Lvl,cool,dry Simultaneous compost leveling, air cooling and drying. CO2,cool,dry Simultaneous CO2 decrease, air cooling and drying. Lvl,CO2,cool,dry Simultaneous compost leveling, CO2 decrease, air cooling and drying. - Inlet Fan Productivity Current measured productivity of inlet fan (%); task received by the VFD of inlet fan (%); manual or automatic mode of task creation. - VFD State of inlet fan variable frequency drive (On/Off) (see paragraph 5.3). Measured inlet fan productivity is displayed on the graph. In this window, using the keyboard of the operator panel, a user can change the control mode of inlet fan, as well as change the state of inlet fan productivity in manual control mode Support Algorithms and Devices Used for Automatic Control Fig.4.13 Support Algorithms and Devices Used for Automatic Control The window displays: - Temp Support Temperature support algorithm (heating/cooling) (see paragraph 5.2.3). - Heating-Cooling Switch Method of switch from heating to cooling and back (manual/automatic) (see paragraph 5.2.3). - Using List of actuators used for temperature control (see paragraph 5.2.3): HE Only coil. OA Only outside air damper. HE,OA Simultaneous use of coil and outside air damper. IF Only inlet fan. HE,IF Simultaneous use of coil and inlet fan. OA,IF Simultaneous use of outside air damper and inlet fan. HE,OA,IF Simultaneous use of coil, outside air damper and inlet fan. - RH Support RH support algorithm (Watering/deWatering) (see paragraph 5.2.4); - Humid-Dehum Switch - Method of switch from Watering to dewatering and back 19

20 (manual/automatic) (see paragraph 5.2.4). - Using - List of actuators used for humidity control (see paragraph 5.2.4): Humid. Only humidifier. HE Only coil. OA Only outside air damper. HE,OA Simultaneous use of coil and outside air damper. IF Only inlet fan. HE,IF Simultaneous use of coil and inlet fan. OA,IF Simultaneous use of outside air damper and inlet fan. HE,OA,IF Simultaneous use of coil, outside air damper and inlet fan. - CO2 Controller Using - List of actuators used to control carbon dioxide concentration (see paragraph 5.2.5): OA Only outside air damper. IF Only inlet fan. OA,IF Simultaneous use of outside air damper and inlet fan. - Тoutside air for cool Maximum outside air temperature at which it is possible to use the outside air damper for temperature control. The temperature support algorithm (heating/cooling) is set in manual mode when switching from heating to cooling and back by pressing the buttons &. The RH support algorithm (Watering/deWatering) is set in manual mode when switching from Watering to dewatering and back by pressing the buttons &. Maximum outside air temperature at which it is possible to use the outside air damper for temperature control may be changed in any way Outside Air Damper and Inlet Fan Control Fig.4.14 Outside Air Damper and Inlet Fan Control In this window the use of the outside air damper and inlet fan is permitted or prohibited to control certain processes: - Outside Air Permission СО2 Decrease Use of outside air damper for CO2 decrease (Yes-permitted, Noprohibited). Air Cooling Use of outside air damper for air cooling (Yes-permitted, No-prohibited). Air Drying Use of outside air damper for air drying (Yes-permitted, No-prohibited). - Inlet Fan Permission Compost Leveling Use of inlet fan for compost temperature leveling (Yes-permitted, No-prohibited). СО2 Decrease Use of inlet fan for CO2 decrease (Yes-permitted, No-prohibited). Air Cooling Use of inlet fan for air cooling (Yes-permitted, No-prohibited). 20

21 Air Drying Use of inlet fan for air drying (Yes-permitted, No-prohibited). By pressing the buttons &, go to the desired line and press. Change the parameter using the buttons &, and press Alarms In this window, the user has the option to permit or prohibit the generation of alarms on various grounds (see section 6). Fig 4.15 Alarms For scrolling the list of alarms use the buttons,,,. To begin and end changes, press Connecting and Disconnecting Temperature Probes In this window, the user has the option to disconnect quickly one of temperature probes. This may be necessary, if the probe fails or for some reason its reading is very different from the readings of other probes. Fig.4.16 Temperature Probes On and Off For scrolling the list of probes use the buttons,,,. To begin and end changes, press. 21

22 4.4 Settings Window Group In this window group, parameters of all cultivation phases are viewed and set. The phase, which parameters are viewed and set, is selected in the first window of settings. To move around the table, press the buttons,,,. To begin and end changes, press First Settings Window Fig 4.17 First Settings Window The window displays: Phase Current phase. Coefficient Coefficient used for compost temperature control (see paragraph 5.2.2). Tcomp., C Set compost temperature, acceptable compost temperature limit, compost temperature hysteresis. Tcomp Variat., C Set compost temperature variation, acceptable compost temperature limit, hysteresis of compost temperature variation. Troom Air, C Set room air temperature, acceptable air temperature limit, air temperature hysteresis. RH,% Set relative humidity, acceptable RH limit, RH hysteresis. СО2, ppm Set CO2 limit, acceptable CO2 limit, CO2 hysteresis. 22

23 4.4.2 Second Settings Window Fig.4.18 Second Settings Window In this window, the user can set permitted operating ranges of control devices in the automatic mode: Cooler Minimum and maximum set positions of chilled water coil. Heater Minimum and maximum set positions of hot water coil. OA Damper Minimum and maximum set positions of outside air damper. CA Damper Minimum and maximum set positions of circulation air damper. Inlet Fan Minimum and maximum productivity of inlet fan. T contr Minimum and maximum control temperature (see paragraph 5.2.2) Third Settings Window Fig.4.19 Third Settings Window In this window, the user can set rates of parameter changes (see paragraphs ): Tcomp Rate of compost temperature change. T room air Rate of room air temperature change. RH Rate of relative humidity change. СО2 Rate of CO2 concentration change. 23

24 4.5 Event Log The controller has an event and alarm log for the last 100 records. In the log the user can view the sequence of alarm occurrence/removal, time and date of event occurrence/removal. The log reports about those alarms, the response to which is permitted (see paragraph 4.3.6). The permitted alarms are displayed as LED indicators on the screen of the operator panel. Simultaneously with the event log record, the controller generates alarms on the operator panel and the light and sound alarm panel board. Detailed description of alarm system is given in section 6. The buttons & are used for viewing. To clear the event log, press simultaneously the buttons &. ATTENTION! The event log can be cleared only by an authorized user (see paragraph 4.6.5). The example of event and alarm log window is shown in Figure Fig Event and Alarm Log The list of controlled events and alarms is given in Table 4.1. Тable 4.1 List of Events and Alarms Event Control Power Supply 220V ON Control Power Supply 220V OFF Login SERVICEMAN Logout SERVICEMAN T Air Failure/Out of Range T Air OK T Comp Failure/Out of Range T Comp OK\ Humidity Failure/Out of Range Humidity OK CO2 Failure/Out of Range CO2 OK Cooler Failure Cooler OK Heater Failure Heater OK Inlet Fan Failure Inlet Fan OK Exhaust Fan Failure Exhaust Fan OK OA Damper Failure OA Damper OK CA Damper Failure CA Damper OK Humidifier Failure Humidifier OK Power Supply 380V ON Power Supply 380V OFF Frost Danger Removed Description State of control power supply 220 V User authorization with elevated access (serviceman), authorization reset. State of air temperature probe and operating mode State of compost temperature probes and operating mode State of RH sensors and operating mode State of CO2 sensor and operating mode State of chilled water coil State of hot water coil State of inlet fan State of exhaust fan State of outside air damper State of circulation air damper State of humidifier State of power supply 380V Frost danger 24

25 4.6 Main Menu For entering the controller s main menu, simultaneously press and hold the buttons & for 2 seconds. Log in to enter and edit parameters and settings. Select the Login menu item and enter a password using the buttons,,,. Serviceman password is To enter the password, press. Menu of the controller s settings is shown in Figure Fig.4.21 Controller s Main Menu To navigate through the menu, use the buttons &. To enter the submenu, use button. To return to the main menu of the operating mode, press and hold the corresponding items of menu levels. for 5 seconds or go to 25

26 4.6.1 AKS Setup Menu Fig AKS Setup Menu 26

27 Control Submenu Description of parameters: Regulation Selects a support algorithm for which the parameters are set. The selection is made from the list: - Leveling, - Heating, - Cooling, - Watering, - DeWatering, - СО2. Settings for each operating mode: Proportion. Factor Proportionality factor of PID controller. Integration Time,sec Integration time of PID controller. Derivation Time,sec Derivation time of PID controller. Regulatory Period,sec Period for calculating the regulatory impact. Drying Submenu Description of parameters: Drying Time, min Duration of the Drying after Watering operating mode. Drying is turned on by toggling the Drying switch, and off either automatically in specified drying time or manually by toggling the same switch. See paragraph for detailed description of control device operation during drying process. Temperature Increase, о С Rise in room air temperature during the drying process. RH Decrease,% Decrease in RH in the growing room during the drying process. Inlet Fan Submenu Description of parameters: Start Delay, sec Time interval after the fan ON, after which VFD enables fan operation. It is used to create a uniform load on the power supply line at the time of renewal (see paragraph 4.3.5). Priority Priority of inlet fan operating mode (Cooling/СО2). It is used only if inlet fan is allowed to be used for both air cooling and CO2 decrease (see paragraph 4.3.5). Humidifier Submenu Description of parameters: Time ON, sec Duration of the ON position of humidifier valve in the humidity increase mode. Time OFF, sec Duration of the OFF position of humidifier valve in the humidity increase mode. Heating/Cooling Switch Submenu Description of parameters: Switch Zone, Switch Time Parameters used for automatic identification of the temperature support algorithm. The current temperature support algorithm (see paragraph 5.2.3) is automatically switched from heating to cooling if the measured air temperature in the growing room exceeds the control temperature (see paragraph 5.2.2) by the value of the switch zone and this condition is satisfied during the switch time. The current temperature support algorithm (see paragraph 5.2.3) is automatically switched from cooling to heating if the measured air temperature in the growing room is lower than the control temperature 27

28 (see paragraph 5.2.2) by the value of the switch zone and this condition is satisfied during the switch time. Humidif./Dehumid. Switch Submenu Description of parameters: Switch Zone, Switch Time Parameters used for automatic identification of the RH support algorithm. The current RH support algorithm (see paragraph 5.2.4) is automatically switched from Watering to dewatering if the measured air humidity in the growing room exceeds the current set humidity (see paragraph 5.2.4) by the value of the switch zone and this condition is satisfied during the switch time. The current RH support algorithm (see paragraph 5.2.4) is automatically switched from dewatering to Watering if the measured air humidity in the growing room is lower than the current set humidity (see paragraph 5.2.4) by the value of the switch zone and this condition is satisfied during the switch time. Circulating Pumps Submenu Description of parameter: Heater Limit ON, % Position of the hot water valve at which the circulation pump turns on. Cooler Limit ON, % Position of the cold water valve at which the circulation pump turns on. RH Probe Settings Submenu Description of parameters: RH Probe Selects RH probe for which the parameters are set. RH probe with #1 is the only one in this modification of the controller. Settings for each RH probe: Offset RH probe offset. Incline RH probe incline. Aspiration Speed Air flow rate around the wet bulb thermometer, used only for aspiration psychrometers. Reset to Default Settings Description of procedure: Reset the control parameters to the factory settings. 28

29 4.6.2 AKS Data Settings Menu Fig.4.23 AKS Data Settings Menu 29

30 For AKS data settings it is necessary to specify the desired PCB and edit the displayed values. Sensor Settings Submenu Filtering Submenu Description of parameter: Filtration Factor Filtration factor for averaging the results of measurements in order to eliminate the influence of external interference. The higher the filtration factor, the longer the device measures and the less the effect of noise. Acceptable values range from 1 to 25. Main Submenu Description of parameters: Sensor # Sensor number. Acceptable range from 1 to 12 for each PCB (see Table 2.4). Type Type of connected sensor (see Tables 2.2, 2.3). Offset Sensor offset. Connected sensors have an error related to the tolerance by the amount of the nominal value. Measured parameter may differ from the actual value by a constant value (Fig. 4.24). For correction of readings, offset is entered per each measuring channel. Acceptable values of the offset range from -9.9 to 9.9 о С. Тинд. о С OFF Without correction без коррекции With с коррекцией correction Тинд. Tind = Тизм. Tmeas + OFF OFF Тизм. С Fig.4.24 Sensor Offset Incline Sensor incline. Possible deviations in sensor reading from its actual value by a certain amount of inclination (Fig. 4.25). A correction factor is entered to correct readings. Acceptable values of the incline range from 0.8 to 1.2. Тинд. о С Without correction без коррекции с коррекцией With correction Тинд. = Тизм. * St Tind = Tmeas *St 20 Тизм. о С Fig.4.25 Sensor Incline 30

31 Lower Limit Lower limit of sensor reading range in the units requested by the user. Acceptable value range from -999 to Upper Limit Upper limit of sensor reading range in the units requested by the user. Acceptable value range from -999 to Digital Input Settings Submenu Description of parameters: Digital Input # - Number of digital input. Acceptable range from 1 to 8 for each PCB (see Table 2.5). Filtering, ms x100 Guard interval to discard malfunction in the corresponding dry contact, a multiple of 100 ms. Acceptable range: from 1 (corresponds to 100 ms) to 20 (corresponds to 2 sec). Polarity Normal contact position of the corresponding dry contact input. Acceptable values: nopen Normally open. nclosed Normally closed. Analog Output Settings Submenu Description of parameters: Output # Number of output. Acceptable range: from 1 to 4 for each PCB (see Table 2.6). Type Output type according to Table 2.9. Offset Output offset, % Acceptable values: from -9.9 to 9.9. Default value: 0.0. Incline Output Incline. Acceptable values: from 0.8 to 1.2. Lower Limit Lower limit of output analog signal. Acceptable values: from -999 to Default value: 0. Upper Limit Upper limit of output analog signal. Acceptable values: from -999 to Digital Output Settings Submenu Description of parameters: Output # Number of digital output. Acceptable range: from 1 to 8 per each PCB (see Table 2.7). Polarity - Normal contact position of the corresponding digital output. Acceptable values: nopen Normally open. nclosed Normally closed. 31

32 Input/Output Diagnostics Submenu AKS controller provides diagnostics of all inputs and outputs of the master controller. To diagnose it is necessary to choose the appropriate PCB and desired input/output (see Tables ). Description of parameters: Designation most of the parameters corresponds to the above-described functional purpose, except for the following: Tech. Units Current value of recalculated control parameter (temperature, pressure, humidity, etc.). Physic. Units Physical parameter value depending on the sensor type (for RTD actual resistance, for analog input actual voltage or current). Output, % Value of analog output in percent Operator Panel Settings Menu Archiving Submenu The structure of Archiving submenu is shown in Figure Description of parameters: Fig.4.26 Archiving Submenu Logging Interval Data logging interval. Acceptable values (time of filling a device memory is indicated in brackets): 1 sec (16 h); 2 sec (32 h); 5 sec (3 days); 10 sec (6 days); 15 sec (10 days); 30 sec (20 days); 1 min (40 days); 2 min (80 days); 3 min (120 days); 5 min (200 days); 10 min (1 year); 15 min (1,5 years); 20 min (2 years); 30 min (3 years); 60 min (6 years). ATTENTION! After changing the logging interval the old data lose relevance and become unavailable for viewing and transfer to PC Visualization Submenu The structure of Visualization submenu is shown in Figure

33 Fig.4.27 Visualization Submenu Input Name Description of parameters: Graph Channel # - Current channel number for which data is entered. Graph Display ATTENTION! Parameters entered in this submenu item are not used in this modification of device. Description of parameters: On-screen Display Graph display mode on the screen when the sensor is switched on. Acceptable values: Yes - Display graph on the screen per the current channel. No - Do not display graph on the screen per the current channel. Display Scale, min Minimum value of the graph scale on the device s screen in the graphical display mode. Acceptable range: from -999 to Display Scale, max - Maximum value of the graph scale on the device s screen in the graphical display mode.. Acceptable range: from -999 to NOTE: Minimum scale value must not exceed a maximum value. Common Settings ATTENTION! Parameters marked as (*) are not used in this modification of device. Description of parameters: * Mode Data display mode. Available the following display modes: - Symbol (text) data display. - Graphical detailed data display. - Graphical shortcut data display. * Graph Speed Graph speed (for the graphical display). Acceptable values: - 0,5 mm/min - 1,0 mm/min - 5,0 mm/min - 10,0 mm/min - 20,0 mm/min 33

34 Scale Type Scale type (for the graphical display). The user can set a general or individual scale of displaying measured readings on the graph. If it is a general scale display, the minimum scale value is calculated as the smallest scale value of all measuring values, and the maximum as the largest scale value of all measuring values. The calculated minimum and maximum values are scaled to the entire visible area of the graph. If it is an individual scale display, the scale of each measuring input is scaled to the entire visible area of the graph individually. Decimal Digit Number Number of decimal digits for displaying the instantaneous values of measurements. You can enter the number of fractional signs in the main modes of displaying the instantaneous values of control parameters. Acceptable values: - Integral (non-fractinal signs, 5 significant digits). - хххх.х (one digit after comma). - ххх.хх (two digits after comma). AutoExit from Menu, sec Time of exit from menu to the main mode of displaying control parameters. The transition is made automatically after a set time, in seconds, since the last press one of the device buttons. If the user Setting has been authorized, then after the exit from menu authorization is reset to the Operator user. Acceptable values: from 60 to 600 seconds. Data Output Time The user can set the length of time for which data will be displayed on the graph Data Transfer with PC Submenu The structure of Data Transfer with PC submenu is shown in Figure Description of parameters: Device Address Device address in the network. Acceptable values: from 1 to 244. Fig.4.28 Data Transfer with PC Submenu Speed (baud/sec) PC transfer rate. Acceptable values: 9600, 14400, 19200, 28800, 38400, 56000, 57600, , baud/sec Date and Time Submenu The structure of Date and Time submenu is shown in Figure

35 General Time Parameters Description of parameters: Fig.4.29 Date and Time Submenu Time Zone - Current local time zone in the region according to GMT. (for Ukraine +2; for Russia +3). Winter/Summer Way of changing clocks from winter to summer time and vice versa. Acceptable values: Automatic - Device will automatically change the clock from winter to summer time forward by 1 hour (last weekend of March) or from summer to winter time back by 1 hour (last weekend of October). Off - Time is not changed. Current Date and Time The current calendar date and time are set in this submenu Reset Submenu The structure of Reset submenu is shown in Figure Fig.4.30 Reset Submenu Reset operator panel settings to the factory settings. ATTENTION! After a reset, the current user s settings will be not available. 35

36 Network Configuration Submenu This submenu is available for rapid diagnostics of exchange between PCBs of the master controller and operator panel. The structure of Network Configuration submenu is shown in Figure Network Scanning Description of parameters: Fig.4.31 Network Configuration Submenu Parameter Name of the selected PCB parameter. Memory Type Type of the specified parameter. Access List of operations performed with the specified parameter. All parameters are read-only and can serve as a source of information to fix the problems connected with data transfer between the master controller and operator panel. Current Configuration Use this menu to configure the connection between the master controller and operator panel. ATTENTION! Do not make any changes to the current configuration, as this may lead to failure of the controller. This submenu is used only by specialists of the manufacturer. 36

37 4.6.4 View Archive Submenu This menu will switch to the mode of data log visualization at a specified time. Archive is divided into 7 pages: Page 1: - Тair Measured air temperature. - Тcontr Control temperature. - Тair.set.cur. Current set air temperature. Page 2: - Rh Measured relative humidity. - Rh.set.cur. Current set relative humidity. Page 3: - Тcomp Compost temperature. - Тcomp.set.cur. Current set compost temperature. Page 4: - Тcomp1 First compost temperature. - Тcomp2 Second compost temperature. - Тcomp3 Third compost temperature. - Тcomp4 Fourth compost temperature. Page 5: - СО2 Measured CO2 concentration. - СО2.set.cur. Current set CO2 concentration. Page 6: - HT Position of hot water valve. - CE Position of cold water valve. - IF Inlet fan productivity. Page 7: - CA Position of circulation air damper. - OA Position of outside air damper. Time and date of data log visualization and archive page numbers are set by the buttons,,, (see Figure 4.32). To exit the menu, select Cancel, to continue select Next. To enter the data, press. Fig.4.32 Entering Start Time of Data Log Visualization 37

38 After setting the time, the logging data will be displayed. The example is shown in Figure Fig.4.33 Data Log Visualization Graph When the entire screen area is filled with data, symbol will be displayed. For viewing data, press button. To move to other pages, use buttons &. To exit the menu, press Login Submenu In this submenu the user enters a password for user authorization (see Fig. 4.34). Press the buttons,,, to select the decade and enter the desired value. After that press. Serviceman password is Fig.4.34 Enter Password Help Submenu In this submenu a user can see the name of device, software version, authorized user name and current device configuration. 38