Ottimizzazione di un Algoritmo di Controllo Embedded per il Total Free Cooling in Sistemi Industriali HVAC

This thesis addresses the design and implementation of a control algorithm for the activation of Total Free Cooling in the newest air-to-water big chillers for data centers by Schneider Electric, developed on a pCO5+ HVAC controller. The main challenge is to find a solution that could be accurate enough, but also able to run on a heavily constrained device like an embedded industrial PLC. This requires a deep understanding of the device and its capabilities, and some trial and error in order to create a version of the algorithm that could run flawlessly. The ultimate goal is to improve the energy efficiency of the machines by providing them with an intelligent decision algorithm that can exploit at best the technique of Total Free Cooling in a reactive and curated way. In particular, the final product is expected to outperform the current approach in terms of reliability and precision, all without significant slowdowns in the program execution. In the industrial and technological infrastructures context, HVAC (Heating, Ventilation and Air Conditioning) systems cover a role that is critical to correct operation, but at the same time account for a meaningful part of the energy consumption. The current global context, characterized by increasing energy costs, stricter environmental regulations, and growing awareness of sustainability issues has made energy efficiency a central objective. Due to their continuous operation and high power demand, HVAC systems represent a key area where energy optimization strategies can generate substantial benefits, as even small improvements can add up to considerable results over time and scale. In this framework, Free cooling represents a fundamental strategy to reduce the energy consumption of the chiller units, by exploiting favorable weather conditions to cool down the water. Total free cooling is an extreme version of this approach that can considerably cut down the power consumption, but it is very delicate as a premature activation can compromise the correct operation of a unit, and a late one brings to a loss of possible savings.