Appendix D: Description of Tests

ID

Test Name

Test Description

52

AHU Pre-functional Checks - Multnomah/Kaplan

This protocol consists of the following:

·       Generic checklist used to gather known problems and possible solutions about facility air-handling units.  It applies to existing buildings only;

·       Generic checklist that documents as installed HVAC equipment characteristics;

·       Generic checklist that documents nameplate data of installed HVAC equipment; and

·       Generic checklist that documents various aspects of the installed location, condition, and operational characteristics of installed HVAC equipment.

56

AHU Functional Performance Verification

This protocol does the following:

·       Helps verify that the airhandler is scheduled properly and that unoccupied setpoints are currently implemented;

·       Helps verify that the airhandler optimum start/stop schedule is setup properly;

·       More clearly defines the purpose for the test; include actual setpoints and the specific reference condition.  If the standard test procedures are not applicable or adequate, document the sequences, tests, and results by first describing the discharged air reset control sequences for each AHU. Next describe test plan in detail. Finally, describe test results and conclusions, including any deficiencies found. helps determine if the HVAC unit can meet setpoint when fan is at 100% of capacity.  It is not testing the actual capacity of the unit.  Test procedures are mostly applicable to VFD controlled fans;

·       Helps determine if the HVAC with VFD controlled fan & flying start can be restarted properly while the fan is still spinning.  This test can damage the VFD;

·       Helps determine if the HVAC unit VFD fan control is spanned properly.  Test is quite subjective;

·       Helps determine if the non-VFD fan control HVAC unit modulates properly.  Test is quite subjective; and

·       provides a number of specific test examples.

64

Boiler Pre-functional Checklist - Multnomah/Kaplan

This protocols documents the differences in what was specified, submitted and installed for boilers, documents the installed condition of the boiler, piping and controls, evaluates an installed boiler's operating characteristics, verifies the function of local boiler sensors, and evaluates the operating characteristics of boiler related valves.  It includes verification checks to confirm boiler characteristics are the same as installed as submitted and as specified.  Installation checks include boiler mounting requirements, piping requirements and electrical requirements. Operational checks include safeties check, combustion test results, and supply water temperature verification. Appropriate temperature sensor calibration checks are included. Very similar to #271.

77

Pump Pre-functional Checklist:

A generic protocol that evaluates the operating characteristics of pump related valves.  Verification checks to confirm pump characteristics match as installed, as submitted and as specified. Installation checks target pump mounting, piping peripherals, startup, balancing, site documentation and electrical connections. Operation checks include start/stop controls or VFD checkout, electrical power issues and specified operating sequences are in place.  Very similar to #284.

78

Cooling Tower Pre-functional Checklist

This protocols documents the differences in what was specified, submitted and installed for cooling towers, documents the installed condition of the cooling tower, related piping, VFD's and controls, briefly evaluates an installed cooling tower's operating characteristics, verifies the function of local cooling tower sensors, and evaluates the operating characteristics of cooling tower related valves.  The protocol begins with confirming all necessary equipment documentation is on site. Installed equipment model number is verified to match approved submittals and/or specification. Installation verification checklists cover the cooling tower installation itself, piping connected to tower and fan variable speed drives (if present) and a general review of electrical service and controls installation.  Operational checks are also included for the tower fan and sump level controls.  Sensor calibration and valve leak-by tests are also incorporated into the protocol

83

Chiller Pre-functional Checklist

This protocol is generic checklist used to gather known problems and possible solutions about an existing chiller, documents nameplate data of installed electric chillers, documents various aspects of the installed location, condition, and operational characteristics of installed electric chillers, and verifies the function of local chiller sensors.  This protocol helps determine the as installed capacity of the chiller by forcing it to its maximum capacity.  This protocol helps verify proper operation of the chiller and its auxiliaries under normal system control. If the actual control sequence differs from that implied by the tests, the user is encouraged to attach a description of the control sequence, the tests that were done to verify the sequence, and conclusions.  Identical to tests in ID 189-194

89

Standard Functional Tests for Chilled Water Systems

This protocol is generic checklist used to gather known problems and possible solutions about an existing chilled water system.  It also includes verifications that the chilled water system can meet design loads (to achieve these conditions may require substantial manipulation of the related systems and controls).  It has tests to verify that a chilled water system operates according to standard start/stop, lead/lag, and chilled water pump speed control sequences of operation.  This protocol encompasses both existing and new chillers. An operator interview is included to review the history of the chilled water system and whatever else the operator knows about it. The document contains a form to collect chilled water system data and compare it to approved submittals (for new equipment). This document is intended to accompany pre-functional and functional checklists. In this spirit, a table is included for tracking the completion of installation and operational checklists and sensor calibrations. A generic sequence of operation is given for a chilled water system. Supporting functional performance tests are provided allowing verification of each section of the sequence of operations provided. Functional tests provide direction in order to verify that each section of the sequence of operation is verified or deficiencies recorded. Specific parts of the sequence of operations reviewed include, verification of system start-up based on demand, proper system start-up, chilled water supply temperature reset control, chiller and tower capacity staging control including all component operations (i.e. bypass valves, discharge dampers, variable speed drives, spray pumps, etc.) and secondary distribution system chilled water pump speed control.

96

Standard Functional Tests for Heating Water Systems

This protocol is a checklist used to gather known problems and possible solutions about an existing hydronic heating system.  Included are general sequences and functional tests for heating plants that start up from a call for heating from the loads and from outside air temperature. Sequence tests also include general heating water temperature reset sequences, boiler staging control, boiler and pump lead/lag control and secondary distribution pump speed control.

103

Standard Functional Tests for Building Exhaust Fans

A set of protocols including:

·       A generic checklist used to gather known problems and possible solutions about an existing building exhaust fan;

·       A generic checklist used to document the availability of documents required to commission a new or existing building exhaust fan;

·       Documentation of the differences in what was specified, submitted and installed for building exhaust fans;

·       Documentation of the installed condition of the building exhaust fan, ducting and controls;

·       A generic observation check that requires the installed building exhaust fan to be observed through its run cycle.  Some detailed requirements are provided for various control types in a separate section entitled Functional Performance Verification;

·       A series of checks and tests that verifies that an exhaust fan operates properly.  Various means of control are mentioned: temperature, manual, time of day, and interlocked.

114

Terminal Unit Prefunctional Checklist and Functional and Performance

This protocol is a series of checks and tests that verifies that an terminal units operate properly in unoccupied, warm-up and occupied modes.  Control sequences are provided for both single duct VAV and dual duct VAV.

115

Energy Management System Standard Commissioning Procedures

Protocols including pre-functional verification checks and functional performance verification:

·       A generic checklist used to document the availability of documents required to commission a new or existing building exhaust fan;

·       A generic checklist used to gather known problems and possible solutions about an existing control system;

·       A generic checklist that documents nameplate data of installed energy management control system equipment;

·       A generic checklist that documents the installation inspection of installed energy management control system user terminal interface and sub-panels;

·       A generic checklist to help verify the proper wiring, point ID, sensor placement and calibration and operation of controlled equipment for an installed energy management control system.

This version is somewhat different than Building Cx Assistance Handbook.

188

Standard Commissioning Procedure for AHUs

This protocol does the following:

·       Collects information from the operator concerning any problems and suggested solutions for the equipment;

·       Documents the specific type of equipment and options installed, and compares this to the design intent documentation or submittals;

·       Documents the installed equipment nameplate data (make, model, serial #, capacity, etc.). If it does not match design documents, comments are made on the form;

·       Checks a number of things from general condition of the installation (cleanliness, access), location of measurement taps, leaks, vibration, electrical measurements, set points, refrigeration system parameters, etc.;

·       Checks the calibration of temperature, pressure, and relative humidity sensors used for control and/or operation of the AHU. It also checks location of these sensors.

This protocol also checks a large number of items for control performance of AHUs. This includes:

·       Scheduled Start/Stop and Unoccupied Setback/Setup Test

·       Optimum Start/Stop Test

·       Discharge Air Temperature Reset Test

·       Fan Volume Full Capacity Test

·       Flying Start Test (VFDs only)

·       Fan Volume Control Normal Operation Test, VFDs only

·       Fan Volume Control Normal Operation Test, non-VFD systems

189

Chiller Procedures

This protocol collects chiller related information from the operator concerning any problems and suggested solutions for the equipment.  It compares basic chiller nameplate data (make, model, serial #, etc.) to submittals. This protocol checks a number of things from general condition of the installation (cleanliness, access), location of measurement taps, set-points compared to design, leaks and vibration. This protocol checks the calibration of temperature sensors used for control of the chiller. It also checks location of these sensors. This protocol checks operating values for temperature, flow, current, voltage, etc, and compares to design under full load conditions.  This is a generic protocol that encompasses both existing and new chillers. An operator interview is included to review the history of the chiller and whatever else the operator knows about it. The document contains a form to collect chiller data with and compare it to approved submittals (for new equipment). General chiller installation issues and current operating conditions are recorded within a general installation checklist. A section is included to record the results of sensor calibration for building control system sensors and packaged chiller sensors. Another section collects data during a full load condition to assess full load operation. A functional performance checklist is provided to evaluate the chiller control system based on how the chiller responds. Each item in the checklist may require testing to determine the appropriate response and the testing procedures are left to the Cx provider to determine. Some of the items warrant static data collection while others require trend data collection.

200

Standard Commissioning Procedure for EMCS

This protocol checks a large number of items for control performance various systems:

·       Pre-verification inspection: EMCS, installed characteristics, controls calibration

·       Functional Performance Verification: Scheduled Start/Stop and Unoccupied Setback/Setup Application Software Test, Optimum Start/Stop Application Software Test, Temperature Reset Application Software Tests

214

Exhaust Air Heat Recovery System Procedures

This protocol gives general questions about the control functions, but does not give any detailed test procedures. It is left up to the user to describe the tests. It is stated that this is done because it is difficult to write a generic test protocol.

243

VFD Procedures

Standard Cx Procedure for Variable Frequency Motor Drives (overlaps with Full AHU procedures).  This protocol measures and calculates various performance parameters for the VFD and compares these to given acceptance criteria, at full capacity and under normal part-load operation. These include maximum frequency, current and voltage imbalance, "flying start" operation (starting against a spinning load without tripping), and input/output performance of the drive.

269

Air Handler Unit Prefunctional Chacklist

This is a generic prefunctional checklist that looks at submitted design documentation, model verification, installation (valves, piping, coils, fans, dampers, ducts, electrical controls, VFD, cabinet and general installation), operation, and sensor and actuator calibration.  Appears to be intended for new installations.

271

Boiler Prefunctional Checklist - DOE/PECI

This is a generic prefunctional checklist for boilers (implied natural gas fired) that looks at submitted design documentation, model verification, installation (gauges, piping, electrical, and controls), operation, and sensor and actuator calibration.  Requires certification from the boiler manufacturer, and specific tests which may be beyond the capabilities of an inspector.  Verification checks to confirm Boiler characteristics are the same as installed as submitted and as specified.  Installation checks include boiler mounting requirements, piping requirements and electrical requirements. Operational checks include safeties check, combustion test results, and supply water temperature verification. Appropriate temperature sensor calibration checks are included.   Very similar to #64.

272

Calibration and Leak-by Test Procedures

All of the prefunctional checklists require calibration of system control and diagnostic instruments.  This is a support document for the checklists that contains simple instructions for performing sensor calibrations, valve and damper operational checks, coil valve leak checks, and isolation valve or system valve leak checks.  The results are recorded on the checklists as applicable.  This document reviews procedures that should be used during sensor calibration and has recommended tolerances for sensors in different applications. Valve and damper stroke calibration procedures are included as well as coil leak checks for 2-way and 3-way valves.

273

Condenser Water Piping Prefunctional Checklist

This is a generic prefunctional checklist for condenser water piping and associated equipment that looks at submitted design documentation, installation (piping, fittings, valves, and gauges), operation and calibration of valves and gauges.  Protocol begins with confirming all necessary equipment documentation is on site. Installed equipment part numbers are verified to match approved submittals and/or specification. Installation verification checklists cover piping itself, how it is installed and supported, and components within the piping such as P/T plugs, valves, sensors, gages, air vents, tanks, strainers and other miscellaneous devices. Flushing procedures, water treatment and chemical treatment are also addressed. Sensor and actuator calibration is also incorporated into the protocol.

274

Chiller Prefunctional Checklist - DOE/PECI

This is a generic prefunctional checklist for chillers that looks at submitted design documentation, model verification, installation (piping, valves, gauges, refrigerant and oil level, wiring), operation, and calibration of valves and gauges.  Very similar to the checklist ID 64 document above. Not exactly the same, but FT guide summary would be the same.

275

Documenting Requirements for Chiller System Startup and Initial Checkout (Example)

This document is an example of what should be created and what information should be collected in a chiller prefunctional test.  It is a short 2 pages, and includes a plan and procedure check off list, a list of reference design documents, and test results for ancillary equipment.  This document provides an example of how to utilize manufacturer's installation and start-up procedures for a chiller and a cooling tower that were furnished for a specific project.  A list of items were created for the chiller and cooling tower with a description and reference to page number from the manufacturers IO&M. Final configurations and settings were required to be submitted for each item.

276

Chilled Water Piping Prefunctional Checklist

This is a generic prefunctional checklist for chilled water piping and associated equipment that looks at submitted design documentation, installation (piping, fittings, valves, and gauges), operation and calibration of valves and gauges.  Protocol begins with confirming all necessary equipment documentation is on site. Installed equipment model number is verified to match approved submittals and/or specification. Installation verification checklists cover piping itself, how it is installed and supported, and components within the piping such as P/T plugs, valves, sensors, gages, air vents, tanks, strainers and other miscellaneous devices. Flushing procedures, water treatment and chemical treatment are also addressed.  Sensor calibration is also incorporated into the protocol.

278

Building Automation System Prefunctional Checklist

This is a guideline for inspecting and confirming the operation of various sensor inputs to a control system.  It has checklists for submitted documentation, model verification, initial setup, and generic instructions and a sample checkout form for each point in the control system.  The control contractor is encouraged to identify better and more comprehensive checkout procedures in their submitted plan.  There is also a prescribed pneumatic system test, and the requirement for calibration of the sensors and actuators for each system, with the results recorded on the system's checklist.

280

Exhaust Fan Prefunctional Checklist

This is a generic prefunctional checklist for exhaust fans (actually, just about any belt-driven fan) that looks at submitted design documentation, model verification, installation (ducts, electrical controls, cabinet and general installation), and operation.

281

Fan-Coil Unit Prefunctional Checklist

This is a generic prefunctional checklist for fan-coil units that looks at submitted design documentation, model verification, installation (ducts, insulation, electrical controls, cabinet and general installation), and operation, and sensor and actuator calibration.  Not much difference from the checklist for AHUs. This document thoroughly addresses prefunctional checklists and operational checklists for a fan coil unit. Unit specifications, physical installation, ductwork connections, line voltage connections and controls are all covered within installation checklists.  Operational checklists verify the control system operates the fan, dampers and valves properly.

282

Heating Water Piping Prefunctional Checklist

This is a generic prefunctional checklist for heating water piping and associated equipment that looks at submitted design documentation, installation (piping, fittings, valves, test ports, gauges, flushing and cleaning plan), operation and calibration of valves, sensors and gauges.  This document consists of checklists to confirm manufacturers’ data has been submitted and checklists for the physical installation of heating water piping, valves and all other piping peripherals. A sensor and valve actuator calibration section is included for these devices mounted in the piping.

283

Packaged Air Conditioning or Heat Pump Unit

This is a generic prefunctional checklist for pumps that looks at submitted design documentation, model verification, installation (cabinet and general installation, piping and coils, fans and dampers, compressor and condenser, ducts, electrical and controls, VFD, TAB), operation (rotation, power, leaking, noise and vibration, safety, sequences and schedules, startup), and calibration of sensors and actuators. This document consists of pre-functional checklists to confirm manufacturer's data has been submitted and for model verification to ensure the installed device matches the submittal and specifications. Pre-functional tests also target physical and electrical installation.

286

Testing and Balancing (TAB) Plan Review Checklist

This document may be used as a guideline for either developing a TAB plan, or checking an existing one for completeness.  It does not take the place of the any recommended formats or procedures in standards referenced in the specifications, but it is intended to augment them.

287

Terminal Unit (TU) Prefunctional Checklist

This is a generic prefunctional checklist that looks at submitted design documentation, model verification, installation (duct and piping connections, dampers, and controls), operation, and sensor calibration.  It is in a spreadsheet format (rather than a document format) having only 16 check points for each terminal unit, but space for including the checks on many separate units.

288

Variable Frequency Drive (VFD) Prefunctional Checklist

This is a summary sheet for consolidating the information recorded from checking the installation of VFDs on fans and pumps.  Space is provided for checks on several pieces of equipment as a table. Most of the VFD protocols are included in the full AHU tests.

289

Cooling Air Handling Unit Functional Test

This protocol checks all of the modes of operation of a cooling air handler unit to verify that it is operating as designed.  The operational checks include damper control, filter pressure drop, freeze protection, and other alarms, and chilled water valve control. The procedures contain 1-5 steps for each functional test in the list below.  The test forms are written for a specific building, but can be modified to fit different projects.  This protocol checks all of the modes of operation of a cooling air handler unit to verify that it is operating as designed. 

·       Device calibration checks for valves, dampers, and VFD

·       Unit startup

·       Fan volume control, static pressure, and isolation damper

·       Economizer

·       Duct static pressure control, alarms, and reset

·       Discharge temperature reset

·       Smoke conditions

·       Warmup control

·       Freeze condition

·       Night purge

·       Minimum outside air

·       Building static pressure

·       Filter pressure drop

·       Chilled water valve

291

Packaged Boiler Functional Test

Protocol includes the procedures and a checklist for determining the current operating characteristics of a packaged hot water boiler.  The procedures include determining the system response to changes in setpoints, and the correct operation of sub-systems such as burners, pumps, and 3-way and isolation valves.  This document begins by thoroughly covering the prerequisites of the testing including but not limited to typical start-up issues, boiler operating safeties and software programming both in the packaged boiler controls and building control system. An area is provided to record sensor calibration results and 3-way mixing valve calibration results. Functional testing looks at the response of the 3-way mixing valve and boiler(s) as the demand forces the heating water supply temperature setpoint up and down through its full range. Functional testing also reviews the system response to safeties being activated, failures occurring and system activation and deactivation within all modes of operation.

292

Packaged Boiler Control Sequences

This protocol describes the sequence of operation for a specific boiler, including what is supposed to happen when setpoints are reached or exceeded.  It is not a testing procedure, but it was probably used to develop one.  This document is a sample system manual from a particular project. It includes detailed overview of the system, operational safeties, seasonal settings, boiler packaged controls and building control system sequence of operation.

293

Boiler System Functional Test

Protocol includes the procedures and a checklist for determining the current operating characteristics of a system of hot water boilers.  The procedures include determining the system response to changes in setpoints including sequencing of boilers in the system, and the correct operation of sub-systems such as VFD pumps.  This document begins by thoroughly covering the prerequisites of the testing including but not limited to typical start-up issues, boiler operating safeties and programmed setpoints. An area is provided to record sensor calibration results. Functional testing procedures are written for a specific system with two 2-stage boilers in the constant volume primary loop and 3 VFD driven pumps for the secondary distribution loop. Testing procedures cover the boiler system response under increasing and decreasing simulated loads, secondary loop control, heating water reset control, boiler efficiency tests, combustion analysis results, flue draft control, safeties being activated, failures occurring and system activation and deactivation within all modes of operation.

294

Cabinet Unit Heater Functional Test

Protocol gives the functional test procedure for ensuring that the thermostat on a cabinet unit heater causes it to turn on and off as required according to the prescribed setpoints.  A valid start is when the fan comes on, the hot water valve opens, and hot air is delivered. This documents reviews prerequisites for functional testing, provides space to record sensor calibration results and incorporates functional testing of the fan and heating valve response to adjusting the space temperature to be above and below the heating space temperature setpoint.

295

Chiller System Functional Test

This is actually a series of 61 functional tests on the different parts of a chilled water system.  The tests include chiller system start-up and staging, miscellaneous chiller system functions, chiller safety controls, other cooling tower functions, and chiller efficiency testing and benchmarking.  The form is designed for the startup of a specific site, but could be adapted for others.  These functional tests were written for a specific project having 3 chillers and matching towers, a primary chilled water loop and a variable volume secondary loop. The condenser water system also contained a heat exchanger to dissipate heat through the cooling towers from air conditioning units. The document includes a test prerequisite checklist which includes general requirements such as system flushing, water treatment, balancing, and all other installation issues complete before testing can begin.  An area is provided to record the results of sensor and device calibration.  Before testing begins, the document provides space to record as-found setpoints and schedules. As this project was completed in the winter, it was necessary to make temporary programming changes to create a false load on the chiller plant.  The protocol recognizes that full loading and staging functions must be completed during the following cooling season. The functional tests target each operational function of the chiller plant stating a narrative description of the sequence of operation, the specification reference, and steps to take during the functional tests, results and whether the system satisfies the specification. The chiller plant functions looked at include system start-up and staging in the chilled water, condenser water and chilled water secondary systems, start-up of back up units upon failure of a lead piece of equipment, chilled water reset function and safety controls.  The heat exchanger operational data is collected and compared with the manufacturer's specifications.

296

Chilled Water System Sequence of Operations

This protocol describes the sequence of operation for a specific chilled water system,  including what is supposed to happen when setpoints are reached or exceeded.  It is not a testing procedure, but It was probably used to develop one.  This document contains a detailed chilled water system summary and sequence of operations for a specific system. The constant volume primary loop is made up of two centrifugal chillers and one reciprocating chiller.  The constant volume condenser water loop has three cooling towers all with low and high speed fans, a bypass valve and sump heater and sump level controls. The condenser loop also has a heat exchanger which rejects heat from computer room air conditioning units. The system overview and sequence of operation are typical of what is necessary for a systems manual.

297

Emergency Power System (comprehensive form)

This is comprehensive test guidance for testing the emergency power system, including the emergency generator, ATS and UPS. It includes test prerequisites, transfer of power, and power failure recovery. The test procedures include measurement of the transient response of voltages, frequencies, and amperages. It also includes verification of equipment operation during a simulated power outage.

298

Emergency Power System (short form)

This is similar to the comprehensive Emergency Power System guidance, but has a less rigorous UPS test.

300

Fin Tube Radiator Functional Test

Protocol gives the functional test procedure for ensuring that a fin tube radiator in a terminal unit responds as it should to requests for heat.  The test is mainly concerned with the operation of the heating coil valve.  Prerequisites include checklists to confirm sequence of operation accomplished within programming or control devices matches approved submittals and primary heating water system has successfully completed all checkouts and functional testing. Functional testing includes confirming the heating valve is normally open, if so specified, and opens and closes as expected based on the space temperature setpoint.

301

Heating Fan Coil Unit Functional Test

Protocol gives the functional test procedure for ensuring that the thermostat on a fan coil unit causes it to turn on and off as required according to the prescribed setpoints.  A valid start is when the fan comes on, the hot water valve opens, and warm air is delivered.  This documents reviews prerequisites for functional testing, provides space to record sensor calibration results and incorporates functional testing of the fan and heating valve response to adjusting the space temperature to be above and below the heating space temperature setpoint.

302

Large Packaded Rooftop DX Unit Test

This functional test procedure includes test prerequisites, calibration checks, and verification of pre-functional checks. Operational tests include off, startup, warmup, capacity control, lockouts, staging, SAT reset, economizer operation, night high and low limits, optimum start, and building pressure. Procedures include trending and observation of terminal units via the EMS/BAS.

362

Chilled Water System Verification Test Procedure

This protocol evaluates the following chiller-related sequences of operation for a chiller with dedicated pumps and cooling tower fans chilled water plant: chiller start; chiller normal stop; chiller fail; lag chiller sequencing; chilled water reset. This protocol evaluates the following primary pump operation sequences of operation for a 2 chiller with dedicated pumps and cooling tower fans chilled water plant: manual on; pump failure; pump control by flow.  This protocol evaluates the following secondary pump operation sequences of operation for a 2 chiller with dedicated pumps and cooling tower fans chilled water plant: pump start; speed control. This protocol evaluates the following cooling tower sequences of operation for a chiller with dedicated pumps and cooling tower fans chilled water plant: fan cycling. This protocol is used to verify the TAB report including chilled water and condenser flows and verification of proper pump impeller sizing.  This protocol evaluates the following chiller related sequences of operation for two chillers with dedicated pumps and cooling tower fans cooling the condenser water system. Chiller plant targeted operational functions include, chiller start, chiller normal stop, chiller lead fail, lag chiller sequencing and chilled water reset. Primary chilled water pump operational functions reviewed include manual on, pump failure and pump control by flow. Secondary chilled water distribution pump operational functions reviewed include pump start and speed control. Cooling tower fan staging to meet demand is also assessed with functional testing.  The TAB report is also verified with regard to chilled water and condenser water pump flow rates.

413

Test and Balance Checkout Functional Test Plan

A generic form for conducting testing and balancing of various HVAC systems.  The protocol checks the actual flow rates and system pressures against design.

414

VAV Cooling Only Terminal Unit Functional Test

A detailed step-by-step sequence of 31 functional test modes of a terminal unit.  Includes airflow capacity tests and operational trending.

415

VAV Dual Duct Terminal Unit with Series Fan Functional Test

A detailed step-by-step sequence of 38 functional test modes of a dual duct VAV terminal unit with a series fan.  Includes airflow capacity tests and operational trending.

416

VAV Dual Duct Terminal Unit Functional Test

A detailed step-by-step sequence of 34 functional test modes of a dual duct VAV terminal unit without a fan.  Includes airflow capacity tests and operational trending.

417

VAV with Hot Water Reheat, Single Duct Terminal Unit Functional Test

A detailed step-by-step sequence of 38 functional test modes of a single duct VAV terminal unit with hot water reheat.  Includes airflow capacity tests and operational trending, and testing of 3-way valves.

418

Unit Heater Functional Test

Protocol includes the procedures and a checklist for determining the current operating characteristics of a unit heater (i.e. a heating fan-coil unit).  The procedures include determining the system response to changes in thermostat set-point.  Prerequisites to functional testing include review of installed equipment to confirm it meets specifications and piping, controls and electrical supporting systems are complete. Functional testing confirms fan and heating coil valve functions as expected when the space temperature heating set-point is changed.

419

Variable Frequency Drive VAV Fan Functional Test

Protocol gives the functional test procedure for a VFD controlling a VAV air handler to a constant duct static pressure.  Includes capacity test to insure that energy use is minimized.

420

VFD Pump Application

This is a functional performance test for a VFD controlling a variable flow hydronic system to a constant differential pressure. The procedures cover design intent documentation, VFD installation (including valve types, differential pressure sensor location, and hydronic system balancing), capacity test, VFD control, and pump staging.

488

HVAC Air-Side

This pre-startup and verification plan covers the air handling equipment for an HVAC system.  The checklist format covers project info and acceptance criteria, equipment descriptions, tool and instrument list, and calibration procedures.  It covers checking the physical installation of the economizer, sensors, ductwork, electrical, controls, T&B, nameplate data, and documentation.

494

Packaged Air-Cooled Chiller

Describes the methodology for commissioning a high-efficiency packaged air-cooled chiller, plus related equipment and controls. Performance parameters to be verified are the chilled water temperature drop and flow rate, the electrical power consumption, and the chiller efficiency (kW/ton) under full and part load operation.  The guideline is a template for developing project-specific verification and functional test checklists.  This document contains pre-startup inspection checklists, verification test checklists and functional performance tests for any Air-Cooled Chiller. Installation and operational checklists are thorough but general and should be developed specific for the equipment targeted. A report includes the commissioning process summary, roles and responsibilities of everyone involved, guidelines on how checklists and tests should be performed on the project and the forms necessary to fill out in order to implement checklists and tests. Forms are provided that list step-by-step instructions for functional testing and recording of operational data collected during testing. Instructions are provided on how to important operating parameters like the chiller efficiency, common expressed in kW/ton, should be calculated.

495

General Commissioning Procedure for Economizers

A multi-part commissioning procedure for economizers that includes the following:

·       Form that includes documentation and training pertaining to economizers that should be expected from the contractor;

·       Forms that list the information required to verify that each piece of equipment that makes up the economizer matches the specification;

·       Forms that list what to check after an economizer installation, including general, dampers, ductwork, mixing, sensors, freeze stats, air filters, and electrical;

·       Form that can be used to check the calibration of sensors installed around an economizer;

·       Form that lists the checks that should be done to the economizer to verify that outside air flows match those given in the specifications.  P14;

·       Form that lists steps to take to verify that the economizer dampers open and close properly in relation to each other and for speed. Page 15 to 16;

·       Form that helps verify that the dampers respond properly to a fire or smoke alarm.  Page 17;

·       Test to verify that the dampers respond properly to various input conditions in different operating modes.  Page 18 to 19;

·       Forms that guide checking the control program or logic diagrams that control the economizer and implement the sequence of operation.  Page 20;

·       Forms that provide a series of field tests that are intended to verify that the economizer operates as it was intended to operate by the designer.  The tests include fans on/off, morning cool-down and warm-up, normal operating modes, fire/smoke alarm, and freeze protection.  Pages 21 to 24;

·       Form that enables testing of the economizer in terms of how well it mixes outside and return air streams upstream of the filter. Page 25;

·       Test procedures that will help verify proper operation of the economizers under normal system control.  Can be used to check that sequences of operation are followed.  Page 26;

·       Procedure that can be used to estimate the savings due to improvements in economizer performance.  It follows ASHRAE's retrofit isolation approach for determining M&V Savings, although it does not describe uncertainty analysis or accuracy criteria. Pages 27 to 28;

·       A short outline of what should be included in the economizer commissioning report. Page 29.

511

General Cx Acceptance Procedure for DDC Systems: Forms

These forms are for documenting the requirements and results of acceptance tests to ensure that a DDC system is installed and programmed to meet the design intent. It includes forms or places for a general system description and operating strategy; the relevant people or firms; a list of sensors, actuators and dampers; a checklist of the software’s capabilities; a checklist of available documentation; hardware nameplate and points list checks; installed program checks; and a table to document test results. The DDC System Operation Trend Tests and DDC System Sequence of Operation Tests provide guidance for writing a test protocol to define the method of identifying acceptable performance. The test protocol requires the following information:

·       Test name: Sequence or condition to be trended

·       Description of control sequence if applicable

·       Prerequisites for initiating test such as verification of sensor calibration of all sensors used to test the sequence

·       Basic instructions including conditions under which the test is to be performed such as season of year or level of occupancy

·       Test duration

·       Measurement method including data to be gathered, method and location measurements required, if special instrumentation are required, measurement tolerances, method of data acquisition, data archival interval(s) and data storage requirements. List the specific points to be trended and if multiple trend reports are required, which points need to be grouped together. If new pseudo or calculated points are required, define the logic or calculation method. Are instantaneous values sufficient or are interval averages required?

·       Sampling.  If large numbers of equipment/systems are involved and trending only a select sample is deemed appropriate, identify the quantity and types of points to be trended.

·       Data analysis, calculations and plotting requirements

·       Results to be obtained including specific measurable or quantifiable criteria for demonstrating acceptable performance

·       Results reporting requirements and recommended remedies for deficiencies

521

General Commissioning Acceptance Procedure for DDC Systems

General procedures for commissioning a DDC system, including 1) verification checks of the DDC interface with installed equipment, subsystems and systems, and 2) functional tests of the DDC system control functions.  The DDC components important to the commissioning effort include central processing/monitoring hardware and software, communications/alarm function, user interface with the DDC system, control functions required for facility operation, local control panels, equipment actuators and controls, and individual monitored points.  The DDC performance parameters can vary widely depending upon the size and complexity of the facility/system being monitored and the level of control delegated to DDC.  Some basic monitored parameters include time of day, start/stop control, temperature, pressure, operating state, proof of flow, voltage, amperage, heat/smoke, lighting levels and occupancy.

522

General Cx Acceptance Procedure for DDC Systems: Example

This is a filled-out, case study type of example showing how to use ID #511.

531

Verification and Functional Performance Test Plan for EMS

Protocols, including verification and functional performance test plan, pre-startup inspection checklist, verification test checklist, and functional performance test checklist:

·       A document that outlines a test plan for commissioning an EMS system - including Project Information, Installation Acceptance Criteria, Performance Acceptance Criteria, Equipment Description, Schedule Requirements, Tools Required, and Calibration Procedures.  Pages 6-33-6-35 in document;

·       An EMS inspection checklist that outlines what to check (pre-startup) in terms of the physical installation of components and tubing, electrical controls, test and balance, nameplate data, documentation, and certification.  Pages 6-36 to 6-38 in document;

·       A checklist that helps verify EMS control strategies and other basic functions (like damper responses, VFD control, schedules, valve responses, graphics, start/stop, trending, alarms, battery backup) work properly, before operating the system.  Pages 6-40 and 6-41.

536

Air Handler EMS Control - Functional Performance Test Checklist

·       These functional tests for air handlers are written for the commissioning provider to verify testing plans written by a contractor. They describe forced trend tests of the supply and return fan control, fire safety venting, fan scheduling, cold deck and hot deck control.  Pages 6-46 and 6-47.

537

Verification and Functional Performance Test Plan for Energy Management System 

This is a collection of verification and performance tests for a DDC system but it also includes sequence of operations for equipment controlled by an EMS system.  The functional tests and sequence of operations listed cover a range of systems, including boilers, chillers, air handlers, cooling towers, and VAV boxes. 

1001

Economizer Evaluation Test

Instructions for evaluating economizer system to determine potential operating problems.  Includes testing of:

·       Dampers, actuators, and linkage systems;

·       System turn down;

·       Mixing conditions; and

·       Sensors and controls.

1002

Exhaust Fan Startup Test

This is an example of a set of startup tests for an exhaust fan.  It includes:

·       Pretest Verification Checks;

·       Preparation steps; and

·       Functional Test procedures such as testing fire/smoke damper operation, controls, flow indicators.

1003

Plenum Leakage Test Procedure

This is a test to identify the air leakage rate in an underfloor plenum, an occupied space, and a ceiling plenum.  It includes the following steps:

·       Isolate the underfloor plenum;

·       Isolate the occupied space and ceiling plenum;

·       Measure flowrate at design plenum static pressure (equals plenum leakage rate);

·       Open terminal unit valves and measure flowrate at design occupied space  static pressure (equals overall leakage rate);

·       Measure flowrate through terminal unit valves (equals occupied space and ceiling return plenum leakage); and

·       Locate sources of leaks.

A Test Guide is available for this test.

1004

Rain Penetration Functional Test

A functional test to determine whether rain will penetrate through outdoor air intake louvers, including the following:

·       Conduct pretest Verification Checks;

·       Set up system to allow for testing during a heavy rainfall;

·       Traverse louver face to measure face velocity; and

·       During a heavy rainstorm, observe and document any rain penetration.

A Test Guide is available for this test.

1005

Relative Calibration Test

This test places the system in a steady state operating mode and then adjusts the return air temperature sensor, the mixed air temperature sensor, the warm-up coil discharge temperature sensor and the air handling unit discharge temperature sensor so that they read the same value when subjected to the same operating condition.  Acceptance criteria are as follows:

1.  With the system in a steady state condition, all sensors read the same value relative to a baseline, with-in their accuracy tolerance prior to adjustment.

2.  With the system in a steady state condition, all sensors read the same value after adjustment.

The test will be performed at two different temperature levels in an effort to provide consistent readings from these sensors under all normally encountered operating conditions.

A Test Guide is available for this test.

1006

Outdoor Air Intake Verification Checks

Verification checks that go beyond the manufacturers recommendations to inspect the following:

·       Sealing, flashing, thermal expansion gaps, bracing;

·       Intake screen;

·       Filters;

·       Actuators;

·       Jack shafts;

·       Blade and jamb seals;

·       Limit switches; and

·       Vertical blades.

1007

Verification Checks Checklist

This is a master checklist of Verification Checks that should be completed.  It includes:

·       Electrical distribution and service equipment;

·       Refrigeration and cooling equipment;

·       Heating equipment;

·       Control and monitoring system;

·       Graphics;

·       Trending capabilities; and

·       Life-safety equipment.

1008

Functional Performance Test: Airside Economizer

Economizer Test – Part of the Model Commissioning Plan and Guide Specifications.  This set of Functional Performance Tests for Airside Economizers that test for the following:

·       Damper position in AHU OFF status;

·       Damper position with AHU in ON status; compressor (or coil valve) and economizer OFF;

·       Dampers in first stage of cooling (economizer ON, compressor or coil valve ON or OFF);

·       Economizer is integrated (economizer ON, compressor or coil valve ON);

·       Dampers go to minimum when outside-air temperature is above economizer setpoint; and

·       Dampers go to minimum when mixed air temperature is below minimum setting.

1009

Hot Water System Pump Test

This is a template to evaluate the impact of partially-closed valves at the discharge of hot water pumps. The procedure will develop a system curve for the pumping system. The intent of the procedure is to gather data; hence there are no acceptance criteria. This test was developed for a particular building and system, and the test purpose section is specific to that system.

1010

Chilled Water System Pump Test

This is a template to evaluate the flow and flow control for a constant speed pump system with 2 pumps in parallel serving 3 way valves with no balancing valves. The procedure will develop a system curve for the pumping system. This test was developed for a particular building and system, and the test purpose section is specific to that system.

1011

Condenser Water System Pump Test

This is a template to look for operational or energy-related problems in a parallel pumping system with two different sized pumps pumping from and to common headers, and serving two different-sized chillers.

1012

Data Collection Procedures for Hot Water Heating Pumps

The purpose of this document is to provide instructions for collecting information on fluid pump(s) that are part of the building’s hot water heating system. It includes recommended tools, data to be collected (including existing documentation and field measurements), tests to be conducted, and templates for the data to be collected.

1013

Envelope Leakage Test- High Rise

This procedure is targeted at determining the building envelope leakage rate. This test is not to ASTM standard E-779-99, but draws on that standard. The procedure is specific to a particular building, but could be adapted to other buildings.

1014

Envelope Leakage Test- Low Rise

This procedure is very similar to the Envelop Leakage Test- High Rise, but adapted for Low Rise buildings.

1015

Blank Test Form for Writing a Functional Test

This form is intended to guide the user through a component level test that is done "on-the-fly" in the field. In general, its purpose is to help the user quickly think through the test prior to executing it. It provides general guidance, a place to outline the proposed test procedure and a place to document the results.

1016

Freezestat Example Test 1

This test is intended to document the operation of the freezestat on AHU1 so that the system can be placed in temporary operation to facilitate the finishing of the drywall. The test assumes that the manufacturer's factory start-up adequately addresses the equipment start-up issues to the extent necessary to ensure that the machinery will not be damaged or jeopardized by the temporary operating mode. Several verification checks targeted at temporary operation issues have been included in the preparation section of the form to ensure that system level issues are addressed before the unit is placed in operation.

1017

Freezestat Example Test 2

This test verifies the freezestat function in the AHU mixed air plenum to ensure that specified actions occur. It is very similar to Freezestat Example Test 1.

1018

Combination Fire & Smoke Test

This test is targeted at verifying the fire and smoke dampers and related interlocks from the individual damper location to the local controller serving them. It does not verify the complete system. This test procedure is divided into two forms. The Tracking and Summary section provides a quick summary of the process and results, provides a way to track the test as it is executed and check off major steps as they are completed, and documents sign off on the completed test. The Procedure Details and Intermediate Data section contains detailed information regarding the execution of the procedure as well as places to record intermediate information used to develop the summary data documented in the first section.

1019

Small Packaged Rooftop DX Unit Test

This is a functional test for small packaged units, including the following equipment as appropriate: supply fans, power exhaust relief fan, economizer, duct smoke detector, gas heat, programmable thermostats, and exhaust fans.

The procedures include documentation of participants, verification of prerequisites, calibrations, verification of prefunctional checks, and the functional tests. The functional tests include evaluation of components when the unit is off, optimum start, heating and cooling staging, economizer operation, scheduling, night high and low limits, fire alarm shutdown, interlocks, freezestat, power failure shutdown and recovery, thermostat programming, minimum and maximum outside air, building static pressure, and cooling capacity.

1020

Example for Writing a Functional Test

This can be used as a generic format for writing a functional test. The test example used is document 1016, Freezestat Example Test 1.

1021

Air-cooled Chiller Functional Test

This test for an Air-cooled Chiller and associated chilled water pumps has sections for documentation of participants, verification of prerequisites, calibrations, verification of prefunctional checks, and the functional tests. The functional tests include startup, minimum chiller flow, minimum ontime, pump failure alarms and correction, outside air temperature lockout, chilled water temperature control and alarms, pump staging, chiller staging, and coil discharge temperature alarms.