D4.3 Report on Assessed Industrialized Energy Generation Kit
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Development of Systemic Packages for Deep Energy Renovation of Residential and Tertiary Buildings including Envelope and Systems
iNSPiRe
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Project Title: Development of Systemic Packages for Deep Energy Renovation of Residential and Tertiary Buildings including Envelope and Systems
Project Acronym: iNSPiRe
Deliverable Title: D4.3 Report on Assessed Industrialized Energy Generation Kit
Dissemination Level: PU
Anton Soppelsa (EURAC) Roberto Fedrizzi (EURAC) Simone Buffa (EURAC) Diego Bertesina (Manens) Romain Nouvel (zafh.net) Mariela Cotrado (zafh.net)
Date: 30 September 2016
This document has been produced in the context of the iNSPiRe Project. The research leading to these results has received funding from the European Community's Seventh Framework Programme (FP7/2007-2013) under grant agreement n° 314461. All information in this document is provided "as is" and no guarantee or warranty is given that the information is fit for any particular purpose. The user thereof uses the information at its sole risk and liability. For the avoidance of all doubts, the European Commission has no liability in respect of this document, which is merely representing the authors view.
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Table of Contents
1 Introduction ...... 1 2 Existing hydraulic modules for residential and office buildings ...... 3 2.1 Solar units ...... 4 2.2 Distribution units ...... 7 2.3 End-user stations ...... 9 2.4 Advanced controls ...... 15 2.5 Market survey conclusions ...... 17 3 Energy management network: a new concept ...... 20 3.1 Energy Hub, Energy Manager and Energy Management Network ...... 20 3.2 Energy Hub ...... 22 3.3 Energy Hub internal modularity ...... 22 3.4 Energy Hub construction ...... 26 3.5 Energy Manager ...... 29 3.6 Software ...... 31
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1 Introduction
This document reports on the development of the Energy Generation Kit carried out in the framework of the iNSPiRe project. The main results presented in this document are the outcomes of the characterization campaigns of the hydronic module prototype at the very core of the kit in terms of Energy Hub, Energy Manager and Energy Management Network.
Beside insulated building envelopes and energy efficient HVAC systems with high nominal performance, intelligent system controls is the third pillar of building energy efficiency. In particular for refurbished buildings, they are the condition sine-qua-none for the achievement of the promised energy savings following the refurbishment measures. The well-known “rebound effect”, resulting in energy savings falling short of expectations after a refurbishment operation, is not purely due to consumption patterns but also often to non-adequate system controls. The new European standard EN15232: "Energy performance of buildings - Impact of Building Automation, Control and Building Management" has been introduced in 2007 by the European Committee for Standardization. It specifies methods to assess the impact of Building Automation and Control (BAC) System and Technical Building Management (TBM) functions on the energy performance of buildings, and a method to define minimum requirements of these functions to be implemented in buildings of different complexities. The diagram below presents the calculation steps of the standard method, from the end-users requirements until primary energy calculation, in the opposite direction as the supply flow. According to this standard and experts like Prof. Dr. Hirschberg from FH Aachen Germany1, optimized system automation and controls may bring alone 20% energy savings in average compared to conventional HVAC system controls. This estimation was for instance the retained objective of the collaborative innovation program HOMES (2006-2010) led by Schneider-Electric, aiming at developing innovative solutions for optimized energy management2. Beside these sizeable energy savings, innovative building automation and controls systems are also motivated by economic reasons. According to some market forecasts3, building automation and controls sector expect to reach nearly 50 billion Euros by 2018, with a compound annual growth rate of 11% for the next 5 years. In the context of the European project Inspire, intelligent HVAC systems controls is a key issue to reach the global project target: 50 kWh/m².a of primary energy consumption after refurbishment for residential and office buildings. This target presupposes the use of renewable energy source among the HVAC systems. It also strongly suggests the implementation of low-exergy solutions; it means systems running with low water temperatures. For the integration of these innovative energy efficient systems into existing
1 Building automation – impact on energy efficiency. Siemens Building Technologies, 2012 2 Project HOMES (2006). Schneider Electric 3 Building Automation & Controls Market (2013 – 2018): By Product (Lighting, Security & Access, HVAC, Entertainment, Outdoor, Elevator Controls, Building Management Systems (BMS)), Application & Geography (Americas, Europe, APAC, And ROW) – February 2013, Markets and markets
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Figure 1 – Diagram energy efficiency calculation; Source: prCEN/TR 15615:2007 HVAC installations (often including remaining piping systems, water storage and end-user units), optimized designed and parameterized control strategies are particularly important. These optimized control strategies rely on integrated hardware components like new sensors, multi-speed circulators, power and electronics components, and interface human-machine. This constellation of components communicate together through specific data protocols (with bus or wireless), forming the controls architecture. The control functions embedded in HVAC generation systems are developed and configured by the manufacturers, who tend to keep them undisclosed because of both guaranty and concurrency reasons. Then, it is hardly possible to neither act on these control functions nor communicate with them to integrate them in a global control strategy. Settings are generally only manually adjustable via a human machine interface, and the manufacturers are the only person able to access data from intern sensors. The possibilities for the integration of innovative control strategies are much more important on the “middleware”, between these HVAC generation systems and the end use.
This document is organized as follows: chapter 2 contains a review of the hydronic modules available in the market in 2013; chapter 3 starts describing the concept of EMN, EH and EM, going then into the details of the prototype construction and operation.
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2 Existing hydraulic modules for residential and office buildings
Since few years, many hydraulic components have been developed by the main international HVAC manufacturers to answer the requirements linked to the socio-energy issues of the 21st century: Individual metering in multi-family house and office buildings (to reinforce consumer awareness, and share the energy bills of centralised HVAC systems proportionally to each end-user consumption Plug-and-play solutions (prefabricated solution, easy mounting, compact with a minimum required installation space) Introduction of renewables systems in existing installation (multi-energy installation)
This chapter consists in a market review of these innovative solutions adapted to single and multi-family houses and small office buildings, from satellite modules or district heating system substation for the heating supply, to fresh water station for the Domestic Hot Water supply, as well as solar unit for the integration of solar thermal panels. This review is far from being fully comprehensive, as this is not the aim; a number of examples are reported as a showcase of the status of today’s technology. The HVAC manufacturers considered in this review are: Lovato, Roth, ICI Caldaie, PAW, Danfoss, Viessmann and Tuxhorn. This list does not aim at being exhaustive. On one hand, several other manufacturers providing similar components exists in the market which have not been included in this document. On the other hand, most of the cited manufacturers offer a much wider spectrum of products compared to what reported. Often this spectrum covers all the 3 applications considered in this document: “Heating”, “Hot water”, and “Solar“, with power range from single family house to 10-20 dwelling buildings. Some manufacturer also provide advanced modules which can manage more complex controls. These modules have been listed in the “advanced control” category. Nevertheless, the survey is believed to give an idea of the currently available solutions to the problem of increasing energy efficiency of HVAC systems by system design and control. In particular, the survey aims at understanding the fitness of the components with regard of the following 4 aspects: Integration of different energy sources; Modularity; Monitoring; Advanced control strategies.
The first aspect refers to the possibility of using the modules to connect different thermal energy sources, such as solar collectors, geothermal probes, pellet or gas boilers, to different loads, such as heat pumps, dry or wet coolers, water-to-air heat exchangers and storages. Modularity is what allows the components to be used as a construction unit for heat distribution systems. Aspects related to modularity are whether or not the component is member of family of components to be used in the construction of heat generation and distribution networks and
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its re-usability in different points of the network. Monitoring covers data acquisition and data access aspects. A module has monitoring capabilities if it measures the at least one physical quantity and can store and provide access to the time evolution of that quantity. Alternatively, if the module does not store information, it must send the reading to an external system providing storage and access to the whole record. The module has only limited monitoring facilities if it measures power flows (heat or electrical) and shows their instantaneous (power) and integral (energy) value in a man-readable form, but not in a machine-readable form. The access to the time evolution of temperatures and thermal and electrical powers flows is necessary to perform the optimization of the energy generation and distribution process. Modules are assigned with the “advanced control strategies” bullet if they provide the architecture and processing power to run complex control algorithms. By complex control algorithms are meant those providing supervisory functions involving multiple inputs and multiple outputs or employing advanced control techniques like e.g. adaptive control, optimal control, fuzzy control, machine-learning.
2.1 Solar units 1.1.1 Pump stations ST 20/11 solar station with integrated regulation unit by Roth
Figure 2 – Roth ST 20/11 solar station with integrated regulation units Roth BW/BWH - Source: Roth
This solar station integrates: a circulator a safety group with relief valve and manometer a fill/drain unit a flow meter a regulation unit.
The Roth regulation unit BW and BW/H are equipped with a microprocessor performing several control function including those required for safe and efficient operation of a solar system. The
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solar circuit can be operated automatically or in manual mode. The Roth regulation unit BW has 1 output (1 x speed controlled) and 4 temperature sensors, while the Roth regulation unit BW/H has 2 outputs (1 x speed controlled, 1 x on/off) and 4 sensors as well as 1 impulse input for measuring quantity of heat, 9 installation schemes pre-installed. In fact, these controlles are manufactured by the Resol company and rebranded by Roth. Resol is specialized in the development of controllers for boilers, DHW satellites, pump stations and solar systems and produces some hydraulic modules as well. This unit is specifically designed to be connected to solar collectors. Although it could be considered a building block for energy management network its use is very specific, therefore it can’t be considered a module easing the integration of different energy sources. Also its modularity, in the sense described above, is limited because of its low reusability. The module does not provide, per se, monitoring features useful for the system optimization. It can be noted however that the same controller unit can be used in more complex situations and if proper external sensors are installed it can provide limited monitoring capabilities. Regarding the controls the units provide quite a number of control functions but no supervision of the overall system, therefore its control functions are not qualified as advanced. Moreover the outputs on the BW and BW/H control units are controlled by relays and can be used to provide 2 or 3 points control only.
2.1.1 Pump and heat exchanger station In comparison with the pump stations, solar transfer modules include an additional heat exchanger, allowing for the heat transfer from a thermal solar plant to a DHW storage tank.
EXOL-AS1 Solar transfer module by Lovato
Figure 3 – EXOL-AS1 - Source: Lovato This module is designed to transfer energy from a solar thermal collector field (up to 80 m²) to a domestic hot water storage tank, via a stainless steel plate heat exchanger. The energy exchanged is displayed on the control. The module is insulated on the fore and backside with EPP.
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This solar transfer module integrates: a stainless steel plate heat exchanger a solar and a charging circulator two 3-way ball valves (one per circuit) 2 fill/drain valves (one per circuit) A safety valve a flow rate sensor and a flow rate regulator a controller
The controller manages both the primary and secondary circuit ensuring the optimum flow rate for heat transfer of the solar thermal circuit. From the point of view of the use of the module in HVAC systems, the same comments as for the previous components apply. The module is very specific and this specificity prevents it to be used as an integration device. As a consequence also its reusability is limited. Regarding the monitoring, it provides limited monitoring capabilities. Finally, although the control algorithms implemented in the controller are not disclosed by the manufacturer, very likely they are limited to the control of the circulators, which does not qualify as advanced.
SLM Units by Danfoss
Figure 4 –SLM-B Unit - Source: Danfoss
The Danfoss prefabricated units SLM, SLM-B and SLM-SWP are designed to transfer thermal energy from the solar circuit (primary side) to the secondary circuit (which corresponds to the heating circuit for SLM, the domestic hot water for SLM-B, respectively the swimming pool for SLM-SWP). The transfer is made via a heat exchanger to decouple hydraulically the two circuits. This unit can be used to cover loads from 52 kW to 367 kW, that is medium-sized and
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large commercial buildings and multi-family houses with correspondingly large solar collector surfaces. The SLM-B unit integrates: an insulated stainless plate heat exchanger a solar and a charging circulator a 3-way ball valve (secondary circuit) a balancing valve 2 fill/drain valves (one per circuit) two safety valves (one per circuit) a thermometer
The solar circulator may optionally be speed-controlled. No controller is integrated in the unit, although some fundamental functions are guaranteed: the primary side circulator is switched on when the temperature in the solar collector is higher than that in the bottom of the buffer vessel. The secondary side circulator is switched on shortly afterwards. In order to avoid calcification of the heat exchanger, the control part must secure, that the secondary side temperature never exceeds 60 °C. This module is clearly a standalone solution to provide heat to specific use from solar collectors. It does not help integration of other energy sources, provide modularity, monitoring nor advanced control.
2.2 Distribution units The distribution units are pre-assembled manifolds, including generally mixing and un-mixing groups, and regulation units.
DN40 Distribution unit by Lovato
Figure 5 – Pre assembled manifolds DN40 - Source: Lovato S.p.A.
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Lovato’s distribution unit DN40 is used for the distribution and management of zoned heating systems. It is possible to configure the system for several types of installations. It is made up of a compensation chamber, a manifold for 2 to 5 heat circuits and 2 types of pumping units: Un-mixing unit (high temperature) Modulating temperature mixing unit (controlled by 3 different electric actuators)
The 3-way valve of the mixing unit is controlled by an electric actuator which is connectable to any type of controller. Temperatures of flow and return is measured using two thermometers. Despite the classification under distribution circuits, this unit is rather specific. It is essentially a manifold for heat distribution, it can connect different loads but it can’t be used to connect an energy source to the network. Its design shows modularity: the manifold itself can be chosen in different lengths so as to serve 2, 3, 4, or 5 load lines; for each line a pumping unit can be added, with or without temperature regulation; the module contains an hydraulic separator unit. Nevertheless, this module is very specific and is not part of a family of products which can be used to build a heat distribution network. The units does not integrate monitoring facilities nor controllers, although it can be equipped with the actuators required to perform control: 3-way control valves, variable speed circulators, and temperature sensors.
HeatBloCs by PAW
Figure 6 – Example of elements from the HeatBloCs family (K33MAX, K31, distrib. manifold) - Source: PAW
The PAW HeatBloCs are pre-assembled groups of fittings for heating circuits being sold in verious nominal diameters, from DN20 to DN50. PAW offers a broad range of heating circuits – from direct HeatBloCs to mixed HeatBloCs with 3- or 4- way mixing valve with/without bypass or thermal control valve. Each module integrates a high-efficiency circulator with ECM technology. The heating circuits are designed such that they can be directly mounted onto a distribution manifold or a mounting plate with thread connections. The single modules can thus be combined without any problems and can be arranged in numerous ways.
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The 3-way valve of the mixing unit is controlled. No further information from the manufacturer is available. The concept behind the HeatBloCs family follows a modular approach. The modules are designed as generic building blocks, increasing the re-usability of the modules (e.g. the temperature regulation block can be used at the generation side or in a DHW unit). A number of different building blocks are offered by the company. The simplest, generic blocks showed in Figure 6 do not integrate control electronics nor a monitoring system4.
2.3 End-user stations
2.3.1 Domestic hot water stations Fresh water station by Roth
Figure 7 – Roth fresh water station - Source: www.roth-werke.de
Roth has developed a compact and fully preassembled fresh water station, with a capacity up to 40 L/min, suitable for use in detached and semi-detached houses, sports complexes, old people's homes, etc. Its stainless steel plate heat exchanger has a large thermal length thus allowing a low primary supply and return temperature. It is completely integrated in the insulation. The Roth fresh water station integrates a regulation unit fully preassembled, pre-set and pre- wired. The primary pump speed control depends on temperature and volume flow, allowing quick and precise regulation of the hot water temperature setting. This speed control is assisted by an electronic flow measurement in the secondary circuit. This provides for the simultaneous recording of the heat flow volume. If required, the circulation pump can be pulse-operated, time-controlled or temperature-controlled. A three-way crossover valve can also be employed, but it is not supplied with the product. This enables very hot primary return water (generated during the operation of the circulation pump) to be returned to the buffer storage tank at a higher level, preserving the colder lower level of the buffer storage tank. The integrated heat
4 Set aside the electronic already integrated in the circulators and in the control valves. The company sells specific modules called “stations” integrating limited monitoring facilities.
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flow volume reading is a straightforward facility for showing the energy used to heat the domestic water. This component is specifically designed as a satellite DHW module. Apart from the application it design has much in common with the ST 20/11 unit, and the same comments apply. As in that unit, the hydraulic components are coupled to an electronic unit for control. Its specific design prevents it to be used as a module for the connection of different energy sources and reduces its reusability. The monitoring is limited and the controls, despite seeming well developed for that application, do not qualify as advanced.
Friwa, domestic hot water module by PWA
Figure 8 – FriwaMini - Source: PAW
Friwa modules are compact and completely pre-assembled stations for comfortable and hygienic domestic hot water preparation. The water is heated up using a heat exchanger on- demand, only when needed - a quick, safe and clean solution. Two models exist for different withdrawal requirements: FriwaMini for 20 L/min and Friwa for 40 L/min. The Friwa module is equipped with a controller, PAW EC1. This unit controls the water withdrawal of the circulation pump in the hot water line. The circulation pump is switched on when the flow sensor signals that a tap has been opened and is switched off after pre-set period of time. The tap point is used as a “remote control”. This component is specifically designed as a satellite DHW module. Apart from the application its design has much in common with the ST 20/11 unit, and the same comments apply. As in
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that unit, the hydraulic components are coupled to an electronic unit for control. Its specific design prevents it to be used as a module for the connection of different energy sources and reduces its reusability. The monitoring is limited and the controls do not qualify as advanced.
2.3.2 Heating/cooling satellite modules PLAY-C1 satellite module by Lovato
Figure 9 – Play-C1 - Source: Lovato s.p.a.
PLAY is a compact distribution module for zone heating systems, suitable for several energy power supplies. Equipped of collector/hydraulic neutralizer, PLAY can manage 2 zones. Each circulation unit is controlled by a 3-way deflecting/mixing valve predisposed for installation of: electrothermic actuator ON-OFF (high temperature) fix point thermostatic actuator (constant temperature) electric actuator (modulating temperature) suitable for Lovato heating controller “LAGO BASIC 1001 and “LAGO 0321” This module is compatible with more than one energy source, the unit can be used to regulate the temperature at the secondary side of the heat exchanger. Its follows a modular approach although the module is quite specific, implementing a configuration similar to that of the DHW modules. Basic control and limited monitoring are provided by external control modules.
Nereix Metering by ICI Caldaie Nereix Metering is an utility satellite for both heating and cooling adjustment, which manage up to two zones. It integrates a metering module (calorimeter) which determines the energy amount, separating cooling from heating mode.
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Depending on the model, these Nereix satellites are equipped with: hot water volumetric meter cold water volumetric meter non-drinkable water volumetric meter thermal energy meter 2-way control valve 3-way control valve The module electronic board interfaces with the thermostat and provides commands to the 2- way or 3-way zone valves, allowing for the achievement of the set-point ambient temperature in the different zones. The module does not pose particular restrictions to the heat source and therefore can be used with a certain flexibility. This module supports monitoring functions: consumption data, measured by the calorimeter and volumetric pulse meter, are acquired by an electronic board installed in the module. Also, connecting an external device called Nereix Master, a PC is able to configure, verify and command different satellite modules. This energy management may be done remotely and/or via internet, using a data SIM contained in a Nereix Master. This module is part of a product family (Nereix) designed to be integrated by advanced control electronics. It will be briefly described In section 2.4.
Figure 10 – Nereix Metering – source: ICI Caldaie
2.3.3 Combined DHW and heating stations and micro DHS substations. Small district heating network substations belong also to this category.
Nereix Clima Module by ICI Caldaie Nereix Clima Module is an utility satellite for heating, cooling and instantaneous domestic hot water production adjustment and metering. Nereix Clima utility satellites can provide several circuits: Double zone (two outputs for mixed circuit) Double temperature (mixed and direct circuit output)
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Nereix Clima Module satellites can be equipped with: cold water volumetric meter not potable water volumetric meter thermal energy meter hydraulic separation between generation and user side via heat exchanger expansion vessel on user side (if separated) steel plate heat exchanger for DHW production circulator for mixed circuit mixing valve to control heating water delivery temperature mixing valve to control DHW delivery temperature
Figure 11 – Nereix Metering – source: ICI Caldaie
The modules are equipped with circulator and mixing valve commanded by the electronic board to control the delivery temperature. This delivery temperature, depending on installed accessories, can be regulated alternatively through: a fixed value depending on external temperature (with external sensor) with ambient compensation (with e-kronos device) From the point of view of the electronic set-up Nereix clima is similar to the Nereix metering station, although this unit is not specifically designed to store the acquired data and provides limited monitoring options. Its controls are not classifiable as advanced.
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Termix VMTD units of Danfoss The Termix VMTD units are complete solutions with built-in water heater and heating system with differential pressure control and mixing loop. With its capacity of 33-85 kW, the Termix VMTD MIX-Q is applicable for single-family houses and for decentralized systems in multi- family houses. The substation is prefabricated with a differential pressure controller, fitting piece and sensor pockets for insertion of a heat meter as well as strainers and ball valves. Furthermore the substation is delivered with a mixing loop including electronic controller, circulator, controls and non-return valve. The heating circuit is designed for direct connection. The differential pressure controller sets the optimum operation conditions for radiator thermostats in order to enable individual temperature control in each room. The mixing loop creates a suitable temperature level e.g. for floor heating. In order to enable a time-dependent temperature control program, a zone valve with actuator and a room thermostat can be included as an option.
Figure 12 – Termix-VMTD- Mix-Q - Source: Danfoss
The domestic hot water is prepared in the heat exchanger and the temperature is regulated with a self-acting thermostatic control valve that controls the DHW preparation by using a flow- compensation principle. The control valve ensures a stable hot water temperature by varying loads, flow temperatures and differential pressure without the need for readjusting the valve. The control valve also works as a bypass keeping the house supply line at 35 °C during standstill. This shortens the waiting periods during summer when the heating system is in reduced operation. This module is a standalone solution of DHW preparation. It can’t be used as a connection unit. It provides limited monitoring facilities and no advanced control in the sense used in this document.
Turxhorn Tubra®-isi Tubra®-isi is an intelligent pre-mounted and pre-cabled system to be connected directly with a buffer tank which combines a fresh water station with pump groups for heating circuits. Its
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size and power are adapted for single family (as central unit) and multi-family houses (as decentralised unit). Heat is distributed through static and mixed heating circuits as necessary. Up to three heating circuits can be integrated. This station integrates: 3 circulators a 3-way mixing valve a heat exchanger a combined flow and temperature sensor optionally a calorimeter This product is for this year 2014 still at the pilot-phase. Consequently, the control functions are in development and then not yet accessible.
Figure 13 – Intelligent multi-purpose pump station Tubra-isi - Turxhorn This station can integrate different heating circuits at the source side and at the load side. Its design and use is however restricted to the applications envisaged by the manufacturer, DHW preparation, radiant space heating and space heating through radiators. The product is member of a family of products (Tubra®) that can be used to build the entire heat generation and distribution network. The components of this family are usually managed by a local controller, operating the pumps and valves therein installed. This typically does not involve advanced control and limited monitoring capabilities.
2.4 Advanced controls Most of the products analysed above can be considered either as small hydraulic building blocks or as hydraulic modules providing specific functionalities (solar modules, DHW modules, heat distribution modules for radiant floors or for radiators, etc.). Has it should be clear from the example above, often building blocks and modules are equipped with control actuators (regulation valves and variable speed circulators) and sensors (temperature, flow, pressure) supporting the advanced control architecture required for effective energy efficiency/saving. Not always they integrate control electronics. When it is integrated, it is used
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to use the module a self-standing unit where the controls and displays are asserved to the specific application (e.g. temperature control for DHW modules, circulator control for solar modules, flow control for distributions modules). When it is not integrated in the module, the control electronics is placed in and external control unit. In most of the cases this is simply a way to control remotely the module, and the control functions implemented in the controller are similar to those found in the integrated controller/display. However, an external controller could be used also to collect measurements and control signals from other modules possibly present in the heat generation and distribution system, or, more generally, in the HVAC system. Some manufacturers (Viessmann, ICI caldaie, Lovato) are following this line of development, as can be viewed by taking a look to their more advanced product lines. In the following, a couple of examples of advanced features will be given, considering the Viessman and ICI Caldaie companies.
Viessmann Vitocom 100, Typ LAN1
Figure 14 – Communication schema centred around the Vitocom 100
The Viessmann company provides specific control units for their devices (boilers, storages, solar thermal systems), which can be integrated, especially in boiler, or external. Regarding the control of solar installations Viessman provides a family of controllers (SCU) specific for this application. In fact this controller is identical to Roth’s BW, BW/H unit, being the one manufactured by the Resol company. More interestingly, Viessman provides a communication unit, Vitocom 100, Typ LAN1 which is designed to connect to supported Viessmann HVAC systems via the LonWorks platform. This unit, together with the Vitotrol Application, shown in Figure 14, offers the possibility of controlling remotely the HVAC installation via internet. Complex control operation such as setting operating programs and time-dependent set-point temperatures are then provided by means of the Vitotrol software which can be installed on a variety of computing platforms, including tablets (iPad) or smartphones (iPhone, Android). Only compatible components In can be connected to the communication unit to make use of these advanced control and monitoring functions.
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It seems that Viessmann follows the approach of placing instrumentation inside the devices of the heat generation instead of in the interconnecting network itself.
Intelligent control system Eterm® by ICI Caldaie Eterm® is the automation and remote control platform of ICI Caldaie heating and air conditioning systems. Currently the ICI products compatible with this platform are their boilers and the modules of the Nereix family. These products are connected with a central controller via a proprietary serial bus. When connected, the ICI products interact with each other under the control of management software in order to completely manage the building, which can be of the complexity of a multi-tenant building. Moreover, Eterm® allows running optimally a complex system managing boilers, solar plants, heat pumps, possibly with co-generation. It can continuously monitor the user’s heating requirements and perform real-time control actions influencing heat generation and distribution. In particular, Eterm® may adjust temperatures and flows based on real requirements (set target temperatures in every room), by controlling boiler circulators, mixing valves and supply pumps to distribution pipe network. Eterm® allows for the setting and monitoring of all connected HVAC installation equipment via software. In detail, it is possible to: Configure the system; Adjust operating parameters; Monitor all operating data; Store consumption data of each user and central system devices; Set room control units; Send commands to room control units (Kronos) via sms; Receive alerts via sms; Carry out technical inspections.
The claims made by the company regarding the control are rather strong. In principle, the plant master unit could perform what in this document is called advanced control strategies. However the manufacturer does not describe the details of the controls nor claims nothing in particular apart a more efficient heat generation and distribution and energy savings resulting from the improved users’ awareness about their consumption profiles. As far as it is possible to understand from the description given by the manufacturer, this platform is definitely oriented towards the next-generation heat distribution and/or HVAC systems. Apparently, it lacks of a rationalization of the hydraulic modules which could bring them to become true building blocks for the interconnection of heat generation and distribution system.
2.5 Market survey conclusions Many European manufacturers have cornered the market of intelligent hydraulic HVAC modules, tackling the issues of renewable heating integration and DHW preparation, with intelligent plug-and-play solutions.
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Most of these modules contain circulators and 3-way valves, controlled with integrated electronic devices providing functions (mostly self-proclaimed “basic”), which should “optimize the energy savings”. Nevertheless, most of the manufacturers keep undisclosed the real function of these controls and very few of them allow for the connectivity with third party intelligent devices, enabling the integration of these local controls into a global control architecture. More generally, we observed a tendency of exclusivity of the HVAC manufacturers: on one hand they emphasize the modularity and flexibility of their intelligent modules, on the other hand, these intelligent modules cannot communicate with modules from other manufacturers (Viessmann Vitocom 100 work only with Viessmann systems, idem for the Lovato/Roth controller units), and then do not support the implementation of advanced control strategies taking into account the interaction of the different modules and components of custom-built systems. In the context of buildings energy retrofitting, where new systems often have to be integrated into an existing HVAC installation, generally with products of different manufacturers, this exclusivity is most of the time counterproductive for the global energy efficiency of the whole installation.
Table 1 – Features provided by the HVAC modules considered in the survey. Manufacturer Model Integration Member Modularity Monitoring Advanced of different of a Control renewable family of energy products sources Roth ST 20/11 ○ ○ ○ ○ ○ Lovato EXSOL- ○ ○ ○ limited ○ AS1 Danfoss SLM ○ ○ ○ ○ ○ Lovato DN 40 ○ ○ ● ○ ○ PAW HeatBloCs ● ● ● ○ ○ Roth DHW ○ ○ ○ limited ○ station PAW Friwa ○ ○ ○ ○ ○ Lovato PLAY-C1 ● ○ ○ ○ ○ ICI caldaie Nerix ○ ● ○ ● ○ Metering ICI caldaie Nerix ○ ● ○ limited ○ Clima Danfoss VMTD ○ ○ ○ ○ ○ Turxhorn Tubra ● ● ● ○ ○ Viessman Vitocom ○ ● ○ ● ● 100 ICI caldaie Eterm ○ ● ○ ● ●
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Table 1, reassumes the results of the survey in a concise form. A black bullet is assigned to the product on the leftmost column if it is considered to show the characteristic in the relative column. The motivations for the classification are given above in the paragraph describing each module. Looking at the table, it is apparent that no pre-assembled module covering all the aspects required for efficient energy retrofitting of buildings seems to exist. In the following chapters, we present a new architecture for the management of thermal energy flows in residential and commercial buildings applications. The proposed architecture addresses all the aspects analysed in this chapter: integration of different energy sources, modularity, monitoring and advanced control. Moreover, it addresses components costs and platform openness as well, aspects not of secondary importance. The proposed architecture is built around the concept of “Energy Management Network”, itself based upon the “Energy Manager” and “Energy Hub” modules. With their integrated control units, open and compatible with standard protocols, the energy hubs aim to become the future elementary building-blocks for HVAC building installation, creating a global and intelligent control strategy.
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3 Energy management network: a new concept
The component at the very heart if the Energy generation Kit is an innovative modular concept for the HVAC installations of small- and medium-sized residential and commercial buildings, particularly fit for refurbished buildings. This concept is realised by deploying intelligent hydronic modules, called Energy Hubs (EH), designed to connect hydraulically to the components of a modern heating and cooling system, and electronically to a central controller, called Energy Manager (EM). The concept is elaborated in the following.
3.1 Energy Hub, Energy Manager and Energy Management Network The EH and the EM are the fundamental building blocks of what, in the context of the iNSPiRe project, is called an Energy Management Network (EMN). The EMN is the result of the connection between EH, EM and the hydraulic components of a residential heating and cooling system, such as solar collectors, water tanks, geothermal probes, heat pumps, backup boilers, radiant panels/ceiling/floor, as illustrated in Figure 15. The EMN concept has been developed in order to reduce the installation costs of the equipment required by efficient hybrid energy generation systems. It is well known that such systems require appropriate management in order to maximise their performance. The EH modules are intelligent connection elements enabling the integration, monitoring and control of the components making up a solar energy system (solar collectors, circulators, electronic valves, water storage, sorption chillers, etc.), although their applicability is not necessarily limited to solar energy systems. The EHs provide hydraulic connections, metering and servo- control features. The EH modules installed in a retrofitted building can be up to few tens, but they are always managed by a single EM module. The EHs are connected to the EM for communication and control purposes. The EM is used to manage the EH in the network and provides to the users and to the maintainer of the system supervisory control and monitoring functions, via a graphical human-machine interface.
Solar Collectors 230 VAC power supply 24 VDC power line Remote HMI Modbus communication
Energy Hub Energy Hub Energy Hub --- Energy Manager
Sorption Chiller
Storage Hydraulic Network Tanks
External sensors Data storage Radiant Local HMI Floor
Dry Cooler Geothermal Probes Figure 15 – Conceptual diagram showing the Energy Hub interfaces and their interconnections.
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In Figure 15 the 230 V AC (light blue) and 24 V DC (red) lines indicate the electrical power flow, while the Modbus communication (black) indicates the information flow. The green and yellow lines represent inward and outward hydraulic connections, the power direction depends on the network topology and the characteristic of the attached components. Also, the connection of the Energy Manager are shown: acquisition of external sensors, HMI, internet connection, which in principle can be used to implement a remote HMIs or monitors or to fed a data storage server. The EMN can be used to implement the control strategies required to achieve the best energy efficiency targets. This usually means implementing one or more of the following items: varying temperature and flow set-points dynamically to generate heat with maximum efficiency, manage optimally the use of different energy sources, minimise auxiliary electricity consumptions, distribute heat with minimal losses, deliver appropriately the end-user with heat, cool or DHW. An example of the controls organization implemented by the EHs and EM is given in Figure 16. Essentially, the EHs (and in part the EM) perform the input and output operation and carry out the computations required to manage the entire system. Data collected all over the plant by the EHs or by the EM itself are sent to the EM for central processing (what is called here global control) and the resulting EM reference signals (commands or set-points tracked by the controller) are sent back to the EH actuators or PID controllers. The whole (Thermal) Energy Management Network is implemented in this way.
Figure 16 – Description of the control layers at of the EH network. The energy hubs boundaries are marked with red dashed lines to stress that EHs integrate hydraulic equipment, sensors and electronic components. The EM essentially coincides with the global controller. Therefore the EMN control system is structured in two levels: the global, or high level and the local, or low level. The low level is essentially proportional, integral, derivative (PID) control, although special control algorithm have been implemented in some cases, for example for the domestic hot water preparation. In other words, the lower level consists of servo-like components employing negative feedback to achieve the control target or improve the control performance. At low level, the aim of control is simple, e.g. the temperature regulation of an EH outlet. At high level, the aim is more sophisticated and control strategies required to orchestrate the entire system are implemented.
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3.2 Energy Hub Each EH is composed of a modular hydraulic part together with an electronic input, output and control (IOC) board. The Energy Hubs are specifically designed to be used for the integration of hydraulic components in the generation or distribution part of an HVAC installation, for domestic hot water preparation, space heating or space cooling applications. Due to their compact sizes and their flexibility, their use is expected to ease retrofitting works in buildings, allowing to connect newly integrated renewable systems (solar panels, heat pumps) with the existing systems in the installation (storage tanks, piping system, end-user units). The EHs are designed to exploit modularity at two levels: 1. They are hydraulic blocks (modules) to be used in the construction of the thermal network, providing at the same time punctual assessment of energy flows and operation information. The EH modules can be built in different sizes (at least two are expected), so as to account for different power needs. They are designed to cover the typical needs of the small- and medium-sized residential applications. This is called in the context of this document external modularity, or just modularity. 2. The main innovation related to this component is the internal modularity: each specialised module used to connect two specific units of the hydraulic system derives from a generic module including all the components possibly needed: o 1 heat exchanger used when an hydraulic separation between two circuits is needed o 2 variable speed circulators at the two sides of the heat exchanger o 2 three-way valves at the two sides of the heat exchanger, allowing for mixing and/or diverting the flows
Furthermore, the EH is equipped with a series of sensors (for temperature, flow and electricity consumption measurement), providing the end-users with monitoring data, as well as giving feedback signals to the controllers implemented in the IOC board and in the EM. The EHs may be equipped with up to 11 sensors, acquired locally by the IOC board: o 8 PT1000 sensors for the measurement of the temperatures o 2 vortex flow sensors for the measurement of the water flow at the two sides of the heat exchanger o 1 electric meter for the measurement of the electrical consumption of the circulator(s).
3.3 Energy Hub internal modularity Indeed, a wide variety of EH variants can be derived from the generic EH model simply by choosing the required components. So far 11 “meaningful” configurations have been identified. The following figure groups five exemplary EH variants (identified by a number between 1 and 5).
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DHW station
EH 1
Pumping unit (for series connection)
Pumping unit with EH 4 temperature regulation
EH 2
Pumping unit
(for parallel connection)
EH 5
Solar station
EH 3
Figure 17 – The five Energy Hub variants used in the following system designs.
3.3.1 EHs as part of the energy generation The figure below shows the combination of energy hubs EH5 and EH3 arranged in series for heat generation using solar collectors and a boiler working as a backup.
EH 5
CR C3 C4
P1 C6 D
C5 V1 P2 V2
C1 C2
EH 3
CR C3 C4
P1 C6 D
C5 V1 P2 V2
C1 C2
Figure 18 – series system integration on generation side, without and with Energy Hubs (grey dashed lines show the components not considered in the energy hub)
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The figure below shows arrangement of energy hubs EH2 and EH3 in parallel to generate heat with solar collectors, a heat pump and a boiler.
EH 2
CR C3 C4
P1 C6 D
C5 V1 P2 V2
EH 2 C1 C2 CR C3 C4
P1 C6 Heat D
Pump C5 V1 P2 V2
EH 3 C1 C2 CR C3 C4
P1 C6 D
C5 V1 P2 V2
C1 C2
Figure 19 – parallel system integration on generation side, without and with Energy Hubs (grey dashed lines show the components not considered in the energy hub)
3.3.2 Case study of a multi-family house The scheme of Figure 20 presents the concrete case of a heat generation installation, which corresponds to a simplified design of the demo case in Ludwigsburg. This shows the combination of four different energy hubs. Heat coming from solar collectors can be supplied for heating and preparation of domestic hot water with energy hub EH3. Energy hubs EH4 and EH1 are used for distribution of domestic hot water. An arrangement in parallel of two energy hubs EH2 is used to supply heat to radiators. Grey dashed lines show the components of the original design of energy hub which are not used for this schema. As detailed in the diagram, all the Energy Hubs of the HVAC installation do not require any heat exchanger.
3.3.3 EHs as part of the energy distribution Figure 21 shows the combination of energy hubs EH3 and EH5 for heat distribution, the first one for generation of domestic hot water and the second one for heating, while Figure 22 shows the integration of energy hubs EH3 and EH2 to build a system working in parallel for production of hot water and heating.
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DHW C5 C6
P1
CR V1 EH 1
P2
C5 C6 D
EH 3 Heat V2 C1 C3 P1 Pump CR V1 C5 C6 C2 C4 EH 4
P1 Heating CR P2 V1
D
V2 C1 C3 P2 C5 C6 C5 C6
C2 C4 D EH 2 EH 2 P1 P1
V2 C1 C3 CR CR V1 V1
C2 C4
P2 P2
D D
V2 V2
C1 C3C1 C3
C2 C4C2 C4
Figure 20 – Parallel integration of a solar collector and a heat pump (grey dashed lines show the components not considered in the energy hub)
C2 C1 EH 3
V2 P2 V1
C5
D DHW C6 P1
C4 C3 CR C2 C1 EH 5
V2 P2 V1
C5
D C6 P1
C4 C3 CR C2 C1 EH 5
V2 P2 V1
C5
D C6 P1
C4 C3 CR Figure 21 – series system integration on distribution side, without and with Energy Hubs (grey dashed lines show the components not considered in the energy hub)
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C2 C1 EH 3
V2 P2 V1
C5 DHW D C6 P1
C4 C3 CR C2 C1 EH 2
V2 P2 V1
C5
D C6 P1
C4 C3 CR C2 C1 EH 2
V2 P2 V1
C5
D C6 P1
C4 C3 CR Figure 22 – series system integration on distribution side, without and with Energy Hubs(grey dashed lines show the components not considered in the energy hub)
3.4 Energy Hub construction The EH is enclosed in a metallic cover that provides water protection and thermal insulation. The outer dimension of the enclosure are 50x62.5x18 cm. The hydraulic components used to manufacture the prototype have all been found on the market. The heat exchanger is manufactured by Swep, the variable speed circulators by Wilo, the three-way valves and control electronics by Belimo, the flow sensors with integrated temperature sensors by Huba Control, the temperature sensors by MINCO, the electric energy meter by Finder. Using components already on the market is part of the strategy to keep low the manufacturing costs of the modules. The assembled EH prototype is shown in Figure 23. The operations of the EH are controlled by an IO board. The block diagram of this board is showed in Figure 24. A central micro-controller is connected to 3 types of input channels and two types of output channels. The 8 input channels on the left are used to acquire temperatures from PT1000 probes (RTD Input). 4 analogic input channels, acquiring electrical signals in the range 0-10 V or 4-20 mA (configurable via hardware), are used to capture the flow and valve position signals. One of the four digital inputs is used as a counter to account for the circulators electrical consumptions. 4 output channels producing electrical signals in the range 0-10 V or 4-20 mA (also configurable via hardware) are used to control the valves and circulators installed in the hub. In addition to that, 4 digital outputs can be configured via hardware as PWM output or be used as digital signals. Finally, the RS485 serial line used for the communication with the EM is shown in the top of the figure. All the functions performed by the EH are normally controlled by this board. This board is designed to be initially programmed and configured by the manufacturer of the EH. The firmware update is not expected to be done on site. Full board configuration, on the contrary, can be done both off- and on-site using the appropriate Modbus tools or the EM.
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The board corresponding to the diagram above manufactured by a subcontractor is visible in Figure 25. Figure 26 instead shows the IO board finally installed in the first EH prototype.
Using electronics extensively as in this hydraulic box has the clear disadvantage of the enhanced production costs compared to passive solutions, which employ balancing valves to control flows and pressure switches to open circuits. On the other hand however, this solution allows for a timely and wise control of the mass and energy fluxes. Moreover, since actuators (valves and pumps) can be controlled based on feedback by the sensors installed, balancing valves and pressure switches are not needed at all in most cases, and this somehow counterbalances the increased production costs. Moreover, having less components installed on the circuits allows for lower pressure losses therefore electricity consumption for water distribution. This objective is also pursued by using surface thermos-resistances setup onto the surface of the copper pipes to measure water temperatures. This strategies produces excellent results in terms of electricity consumption: in the demo case of Madrid (D7.4b), the electricity consumption to distribute water into radiant ceilings producing space heating & cooling for 50 m2 apartments is in the range of 5-10 W. The electricity consumption to distribute DHW in the mains of 5 apartments is in the range of 40-50 W.
Electronics Flow meter
3-way valves Variable -speed pumps Temperatur e sensors
Figure 23 – Prototype of the EH during test operations.
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OUT IN Connector Connector RTD Input 0-10V/4-20mA Output Driver
RTD Input 0-10V/4-20mA Output Driver RTD Input RS 485 Transceiver 0-10V/4-20mA RTD Input Output Driver
0-10V/4-20mA RTD Input Output Driver
MM RTD Input UU AADDCC uC X X DDAACC DDAACC PWM/Digital Out RTD Input
PWM/Digital RTD Input Out
Connector for Programming PWM/Digital Out 0-10V/4-20mA Signal Cond. PWM/Digital Outr 0-10V/4-20mA Signal Cond. l l l l e e e e v v v v n n n n
0-10V/4-20mA e e e e I I I I L L L L
l l l l / / / / a a a a Signal Cond. r r r r t t t t e e e e i i i i t t t t g g g g i i i i n n n n D D D D u u u u o o o o
0-10V/4-20mA C C C C Signal Cond.
Figure 24 – Block diagram of the IO board installed in the EH.
Analogic Analogic outputs inputs
Modbus connector
Digital RTD channels outputs
Digital inputs Power-supply connector
Figure 25 – First experimental tests using a digital oscilloscope during the development of the IO board c/o the sub-contractor. Power supply connector bottom left, serial communication connector top right, programming connector centre.
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Figure 26 – The electronic equipment of the Energy Hub and its container. Terminals for power supply and serial communication, electrical energy meter and control board are visible.
3.5 Energy Manager The EM is essentially an electronic device equipped with an industrial personal computer with integrated touch screen and the DC power supply for the whole network. One of the IO boards designed for the EH is also included to allow acquisition of external sensors not supplied within the EHs. This may be the case if the temperature sensors are placed in water storages or pyrometers are used to read the value of the instantaneous irradiation on the solar collectors. Also the EM is enclosed in a metallic box providing protection against dust and sprayed water. Figure 27 shows the EM. The touch screen provides the necessary local user interface to interact with the EM and all the EHs in the network. The dimensions of the enclosure, 50x40.5x20 cm, are similar to those of the EH, and to leave enough ventilation space around the electronic components.
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Figure 27 – Outlook of the Energy Manager prototype. The picture shows the touchscreen of the industrial PC during operations.
Figure 28 – Outlook of the Energy Manager when opened. The backward side of the panel PC is clearly visible. The panel PC is connected to the 24 V DC power supply and to the IO board via Modbus for communication.
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Figure 29 – Details of the Energy Management internals. The 200 W power supply is visible on the right, the IO board at the centre.
3.6 Software A significant effort has been spent on developing the EH and EM software.
3.6.1 Structure of EH software The firmware of the IO boards for the EHs has been developed in house to allow calibration and measurement from the foreseen sensors, to allow full configuration of the actuators’ PIDs from the EM interface, and to allow R485 MODBUS communication among all EHs (with each other) and the EM.
3.6.2 Structure of EM software The EM software has been elaborated with the final stages of the development of the IO board. The main function of the EM is the supervisory control of the EMN. Also, the EM provides the human machine interface (HMI) to enable the configuration and the inspection of the system by the human operator or plant owner (monitoring) and data logging, a fundamental feature to assess the energy performance of the system. The EM allows also the connection with remote operators through the www. The details of the EM implementation are quite complex as the software is rather large. It is however not so difficult to grasp how it works at high level. During the initialization phase after start-up or reset the EM scans the Modbus for the presence of attached EH. In this process it constructs dynamically the data structures required to manage all the EH on the bus working correctly. After the completion of the scan, the EM maintains an internal map of the current situation of the EMN: it knows the number and type of connected hubs and starts automatic operation.
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In automatic operation the EM runs the main system controller, which has been tailored to the specific system before installation. The EM can be run by experts on field manually. In this case each hub is under control of the operator, who can control manually the actuators within each EH. Finally the EM can be switched to a configuration mode. In this case the main control loop is suspended and the operator can use the Modbus to change the configuration of the EHs’ actuators operation or the EM itself. In order to hide the technical details to the untrained users or owners of the installation, the EM interface is in fact manifold. The basic interface is the user interface. Most of the complex features of the EM are hidden when this interface is activated (default). The EM has been designed to work using a total three interface levels (called operating modes) user, operator and set-up. Table 2 shows the interaction between operation modes and user interfaces. Table 2 - Running mode accessible from the given operating mode. Automatic Manual Configuration User YES NO NO Operator YES YES NO Set-up YES YES YES
An example of the EM interfaces seen by the user at the complete level is given in Figure 30 to Figure 37. Notice that the pictures of the user interfaces are taken from the EM monitor during operation, and their purpose is to give to the reader an idea of the EM complexity. This is not the complete set of the user interface windows of the EM.
Figure 30 – Main interface of the EM, visible in all the view modes.
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Figure 31 Daily report window.
Figure 32 – System diagram window.
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Figure 33 – Operation tab of the EM while in the Manufacturer view.
Figure 34 – Waveform windows for the operator view.
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Figure 35 – IO channels configuration interface.
Figure 36 – Local control configuration interface.
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Figure 37 – Alarm logger interface
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