Programming the AHU

Tasks
 In this exercise you will create a Function Block Program using the existing
macros which is a part of the Function block editor.
 Some free programming is needed.
 You need to create bindings manually in the editor.
 Follow the steps if you find it to difficult, if you want a bigger challange,
make the programming using just the information found here.
 The solution to this exercise can be found in Appendix 10 (A10)
 Starting point:
 This is the specifications for the project:

Starting Point
This is the specification of the AHU
Steps
Operation of AHU01

1. Air handling unit in operation

Startup sequence

1. The AHU01 is switched on by means of the time schedule.

2. During start up, supply air damper FZ01 and the exhaust air damper FZ19
will open.
3. Then fan EF01 starts, after a delay fan SF01 starts.
4. Fan EF01 interlocks fan SF01.

Outside normal operating hours, the unit could be switched on by means of the
hand switch HS16 (user can define the “on time” for the afterhours). Pressing
the switch once starts the air handling unit and the second press stops it.

Temperature control sequense

Supply air temperature TE10 is controlling the temperature control sequence.

When heating demand increases, control takes place using the following
sequence:

1. The remote processing unit controls Heat exchanger circuit and increases
heat recovery by means of the valve FV02.
2. Heating valve FV04 opens to increase heating, so as to maintain the
desired temperature sensed by TE10 (supply air).
3. Circulating pump P04 runs continuously and gives an alarm when it stops.
4. Set point in heating case is 19°C.
5. When cooling demand increases the valve FV05 is used for cooling stage.
Cooling pump P05 starts when there is a cooling demand. During heating
period the cooling pump exercises once a week. Set point in cooling case is
22°C.
6. The heat recovery circuit pump starts when there is a demand (valve FV02).
The pump exercises once a week. If the pressure measurement PE02 value
goes under 1 bar, it will trigger an alarm.
7. The efficiency of the heat recovery is also calculated.

Fan speed control

1. If the outdoor temperature TE00 is lower than -

running on 60% speed otherwise on 90% speed.
2. Plant shutdown

When the plant stops, the supply air damper FZ01 and exhaust air damper
FZ19 closes, pump P04 is running and the supply fan SF01 and exhaust fan
EF01 are stopped.

The return water controller will modulate the heating valve FV04 so as to
maintain the desired return temperature sensed by TE04.

3. Protection

The freeze protection (software) is triggered when liquid temperature is low

(under +6°C) in the heating coil return pipe (TE04) and stops the unit SF01 and
slave exhaust fan EF01 to avoid bursting the coil. The heating pump stays
running. Control is similar to plant shutdown. If the circulations pump stops the
AHU stops. Freeze protection is reset by means of the hand switch RS04.

If the return temperature sensed by TE04 goes below a set point the return
water controller will take over modulation of the heating valve FV04, to prevent
freeze protection (software) from tripping.

When the filter guards activates the alarm is triggered and the AHU continues
running.

4. Programming

Steps:
 Create a new Function Block Program, name it: Exercise_10 – AHU1
 Program the function according to the task description, or follow this flow:
1. In the editor, Start finding proper macros for the project - Right click “Load
Macro”
2. Create the “Running control” that controls when to run the AHU using a time
schedule..
a. ...\Macro Library Function Block\Airhandling\Function\Running
Flag.AUT
3. Create the “Timer (start/stop)” button for the after hours function.
a. ... \Macro Library Function
Block\Miscellaneous\Timers\Timer2.aut
4. Create the start/stop control of single speed fans with xor alarms (fan
interlock).
a. ...\Macro Library Function Block\Airhandling\Function\ssfan2.aut
b. Pressure switch indicates if the fan is running or not (EF01_Ind,
SF01_Ind)
5. Create the supply and exhaust dampers control.
a. controlled by running indication
b. no ready made block – “just indication (BI) to output (BO)”.
c. can be made by binding in the ES
6. Create the speed drives speed control.
a. no ready made block
b. use analog multiplexer (mux) to select a proper signal (PVR).
7. Create the freeze alarm to prevent the AHU battery from freezing.
a. software resetting
b. connect alarm to the alarm lamp (BO)
c. ...\Macro Library Function Block\Airhandling\Function\Freeze.aut
8. Create the cooling pump, with manoeuvre alarm.
a. starts according to control signal
b. exercises once a week
c. ...\Macro Library Function Block\Airhandling\Function\Pump
9. Create the heat recovery pump with manoeuvre alarm.
a. the same as cooling
b. ...\Macro Library Function Block\Airhandling\Function\Pump

10. Create the PID loop. Cooling, heating and HEX control in sequence.
a. ... \Macro Library Function Block\Airhandling\Control\Heat HEX
Cool.AUT
11. Create the supply control to calculate the temperature setpoint
a. ... \Macro Library Function Block\Airhandling\Control\Supply
Control.AUT
12. Create the efficiency calculation (TE21 and TE21)
a. .... \Macro Library Function Block\Airhandling\Calculation\HEX
Efficiency.AUT
13. Create the heating pump, with manoeuvre alarm.
a. likewise cooling
b. ...\Macro Library Function Block\Airhandling\Function\Pump
14. Create the control of the return water (prevents the heating battery to freeze
when AHU is stopped or when outdoor temperature is low and need for
heating is low).
a. ...\Macro Library Function
Block\Airhandling\Function\minHeat.aut
15. Create a pressure alarm for the heat recovery circuit
a. no readymade block
b. PE02 select (create ALARM object in the ES)
16. Create inputs for additional measurements
a. TE02 Heat recovery liquid temperature
b. TE03 Temperature after HEX, before heating
c. TE05 Temperature before cooling
d. TE16 Room temperature
e. PE 10 Supply duct pressure
17. Create inputs for the filter alarms (inlet air and return air filter).
a. PDA01, PDA19 (create ALARM object in the ES)
18. Create inputs for speed drive alarms (indicating that something is wrong in
the speed drives).
a. SC19, SC08 (create ALARM object in the ES)
19. Test the programmed functions using either the “Live View” in Work Station,
or the “Simulation Mode” in the Function Block Editor.