Test and Balancing

1
Test and Balancing

• Functional Performance Test
• Presented by
• John Shelander and Dan Acri

2
System Description

• The air handling (AHU) unit is a variable air
  volume (VAV) unit with hot water preheat, chilled
  water cooling with outside air economizing,
  variable frequency (VFD) drives on both the
  supply and return fans, and a supply air
  humidifier.

3
System Components The system consists of

• Air Handling Units No. 1, 2, and 3
• Supply Air Fans No. 1, 2, and 3
• Return Air Fans No. 1, 2, and 3
• Circulating Pumps P-1, 1A, 2, 2A, 3, 4, 5
• Exhaust Fans No. 1, 2, 3, 4, and 5
• Chilled Water System
• Hot Water System

4
Modes of Operation

• Occupied
• Economizer
• Unoccupied
• Warm-up
• Alarms and Safeties

5
Purpose

• Demonstrate Air handling Unit and associated
  components function as an integrated system, to
  produce the design intent of the systems and
  equipments as installed.

6
Points to consider during planning

• Estimated Duration
• Acceptable Results
• Affect on Building Systems
• Test Conditions
• Staffing
• Test Instruments Required

7
Staffing

• Owners Representative
• Mechanical Engineer
• Construction Manager/General Contractor
• Commissioning Agent
• Mechanical Contractor
• TAB Agency
• BAS Contractor

8
Special Test Equipment Required
9
Initial Requirements
Verify affected systems are in full operation,
with SVC complete and equipment interface checked.

• Air Handling Unit No. 1, 2, and 3
• Return Air Fan No. 1, 2, and 3
• Exhaust Air Fan No. 1, 3, 4, and 5
• Chilled Water System
• Heating Water System

10
Verify System Verification / Start-up Checklist
are complete

• Air Handling Unit No. 1, 2, and 3
• Return Air Fan No. 1, 2, and 3
• Exhaust Air Fan No. 1, 3, 4, and 5
• Chilled Water System
• Heating Water System

11
Verify BAS point interface check is complete

• Air Handling Unit No. 1, 2, and 3
• Return Air Fan No. 1, 2, and 3
• Exhaust Air Fan No. 1, 3, 4, and 5
• Chilled Water System
• Heating Water System

12
Verify testing and balancing is complete.

• Air Handling Unit No. 1, 2, and 3
• Return Air Fan No. 1, 2, and 3
• Exhaust Air Fan No. 1, 3, 4, and 5
• Chilled Water System
• Heating Water System
• Pencil copy of the TAB Report

13
Verify Fire Alarm System interface is checked

• Obtain a copy of the fire alarm testing for
  record purposes only.

14
AHU-1 Sequence of Operation
Occupied Mode
The air handling (AHU) unit is a variable air
volume (VAV) unit with hot water preheat, chilled
water cooling with outside air economizing,
variable frequency (VFD) drives on both the
supply and return fans, and a supply air
humidifier. When indexed to the occupied mode,
the return air smoke damper and the supply air
smoke isolation damper will open and when it is
proven by their end switch, the return fan (RF-1)
shall start and the VAV terminal units shall be
put into the occupied mode. The supply air smoke
damper will open 15 seconds (adj.) after the
return air fan is on. When proven open by its end
switch, the supply air fan shall be energized and
operate under its control sequence.
15
Supply Fan Control
When the AHU is indexed to start, the minimum
outside air, relief air and return air dampers
shall be controlled as indicated in the contract
documents. When the supply fan is de-energized,
the outside air and relief air dampers shall
close and the return air damper shall open, and
the chilled water coil control valve shall be
closed. A supply duct static pressure censor and
control shall modulate the supply fan variable
speed drive (VFD) to maintain the supply duct
static pressure set point (1.0 IWC, adj.) A
potentiometer in the unit control panel will
allow adjustment of the supply-return fan motor
speed tracking control loop offset. The
panel-mounted controller digital output will
allow the control loop offset to equal the
potentiometer set point (RAF 10 slower the SAF,
adj.) when fans are operating in normal occupancy
modes. The offset will be removed during morning
warm-up and night setback modes.
16
Minimum Outside Air Damper Control
A minimum position potentiometer in the unit
control panel will allow adjustment of the
outside air damper position. The CCMS will
control a panel mounted digital output that will
allow the outside air damper to open to the
potentiometer minimum set point. The field
controller will energize the air damper minimum
position output when the supply fan motor is
energized during the time clock occupied period
and the return temperature is above the warm-up
mode set point (67 F, adj.), or the supply air
fan has been operating in the occupied mode for
the warm-up period set point duration (600
seconds, adj.). The field controller will
de-energize the air damper minimum position
output when the supply fan motor is de-energized,
or the unit is not operating in the time clock
occupied period, or the return air temperature is
below the warm-up set point and the supply fan
has not been operating in the occupied mode for
the warm-up period set point duration.
17
Return Air Damper Control
A mixed air static pressure control loop will
modulate the return air damper position to
maintain the outside air volume at set point when
the unit is operating. The CCMS field controller
will control a panel-mounted controller digital
output that will allow the return air damper to
modulate in response to the mixed air static
pressure control loop. The CCMS field controller
will energize the digital output and enable the
return air damper control when the supply fan
motor is energized. The field controller will
de-energize the output and fully open the return
air damper when the supply fan motor is
de-energized. A hardwire interlock will override
the field controller and disable the return air
damper close enable when the unit supply fan
motor is de-energized.
18
Return Air Damper Close
A static differential pressure sensor will be
installed between the outside air reference and
the mixed air stream and connected to an analog
input of a panel-mounted digital controller. The
high side of the sensor will terminate at the
outside air pressure reference. The low side of
the sensor will terminate at the mixed air
pressure probe. When the outside air damper
minimum position control is enabled, a controller
analog output will modulate the return air damper
closed as required to maintain the mixed air
static pressure at set point (determined by air
balancing contractor, - .2IWC, adj.). On a fall
in static pressure below set point, the dampers
will further close to increase the outside air
volume. On a rise in static pressure above the
set point, the damper will further open to
decrease the outside air volume.
19
Discharge Air Temperature Control
Control of the hot water and chilled water coil
valves will be enabled when the supply fan motor
is energized. A supply air temperature sensor
controller input shall modulate the hot water and
chilled water coil valves as required to maintain
the supply air temperature set point (55? F,
adj.). A hot water coil leaving air temperature
sensor controller input shall override the supply
air temperature sensor and modulate the hot water
coil valve as required to maintain the coil
leaving air temperature above the low-limit set
point (50? F, adj.).
20
Humidity Control
A supply air humidifier shall be controlled by
the manufacturers controls to maintain return
air humidity set point. ATC has no work
associated with this. The ATC shall supply a
redundant return air relative humidity sensor to
be used for monitoring only. The return air
humidity value will be displayed on the ATC
graphics screen.
21
Economizes Damper Enable
The CCMS shall monitor the (Sequence indicated
economizer to be based on outside air temperature
verse return air temperature, coordinate with
university to see if control by enthalpy is
acceptable.) return air and outside enthalpies,
and enables the OA/REL dampers for economizer
operation when the outside enthalpy is less than
the return air enthalpy.
22
Morning Warm-up Control
Within an hour after system initial startup, the
unit shall be indexed into the warm-up mode or
cool down mode whenever the return air
temperature falls below the warm-up set point,
67 F (adj.), or rises above the cool down set
point (76, adj.). When operating in the warm-up
or cool down, the supply and return fans shall be
started and the outside air damper and relief
damper shall be held closed. During warm-up
mode, the outside air and relief dampers shall be
held closed, the return air damper shall be help
open, the DAT set point shall be raised to (70
F, adj.), and the VAV terminal dampers shall
modulate in a hot primary air state to maintain
their individual set points. When the return air
temperature rises above the warm-up off set point
(2 F above cool down set point, adj.), the unit
shall be indexed to the occupied mode and the VAV
terminal units shall be indexed to normal
operation with local zone sensors regaining
control of associated VAV terminal units in the
cooling state.
23
Unoccupied Control
When the AHU system is indexed to the unoccupied
mode, the supply fan shall be de-energized. Upon
a fall in any zone air temperature below the
unoccupied set point (55? F, adj.), the supply
and return fans shall start, the outside air and
relief dampers shall remain closed, the return
air damper shall remain open, and the unit and
associated VAVs shall operate in the occupied
mode. When the space temperature rises to the
unoccupied off set point (58? F, adj.), the
supply fan shall be de-energized.
24
Static Pressure High Limit Interlock
A manual reset high static pressure switch
mounted in the supply duct shall stop the supply
fan, return fan, close the outside air and relief
dampers and open the return air damper when the
supply duct static pressure rises above the high
limit set point (7.0 IWC, adj.). The CCMS shall
monitor the SA static pressure high limit switch
and initiate a CCMS alarm if a high static
condition exists.
25
Freeze Protection
When the outside air temperature falls below the
low limit set point (35? F, adj.), then the
heating coil circulating pump shall be energized
and run continuously. When the outside air
temperature rises above the low limit off set
point (41? F, adj.), the heating coil circulating
pump shall be de-energized. On a fall in the
mixed air temperature through the control loop
proportional band (47? F to 43? F, adj.), the
mixed air low limit selector will override the
economizer signal by taking the lower of the DAT
economizer damper signal and the mixed air lower
limit signal to modulate the economizer damper to
the minimum outside air set point position. When
the mixed air temperature falls below mixed air
hot water valve set point (38? F, adj.), an alarm
will be indicated on the CCMS. On a fall in mixed
air temperature through the control loop
proportional band (40? F to 37? F, adj.), the
field controller will start the hot water (HW)
circulating pump.
26
Freezestat Interlock
A freezestat shall be mounted on the entering air
side of the chilled water coil and shall be
connected through hardwired interlocks to
de-energize and disable the supply and return
fans, close the outside air and relief dampers,
open the return air damper, drive the chilled
water (CHW) and hot water (HW) valves open, start
the hot water (HW) circulating pump, and initiate
a CCMS critical alarm, if the chilled water coil
entering air temperature fall below the low limit
set point (37? F, adj.).
27
Smoke Detector Interlock
Smoke detectors located in the supply and return
ducts shall de-energize and disable the supply
and return fans, close the supply and return air
smoke dampers, close the outside and relief air
damper and open the return air damper, and
initiate a CCMS alarm if product of combustion is
senses.
28
Filter Status
The CCMS shall monitor filter status via a
pressure differential switch connected to a local
controller and initiate a CCMS alarm when dirty
filter condition exists.
29
Functional Performance TestAir Handling Unit 1

• Test Mode Occupied
• Start Date
• End Date
• Agent
• Contractor
• Owner

30
Record the initial temperatures and humidity
31
Test ModeNormal - On
32
Command the system through the BAS system
Verify the follow occurs. (All operation are to
be automatic, no intervention from the operator.)
The return air smoke damper and supply smoke
isolation dampers open (the supply damper is
delayed for 15 seconds before it will open), when
proven open, the return air fan will start and
then the supply air fans start, the return air
fan is set to operate at 10 slower then the
supply air fan. VAV terminal will be indexed to
occupied mode. ? Pass ? Fail ? Retest
33

• The outside, relief and return air dampers will
  move to their correct position, the outside to
  its minimum position, the relief air to its
  minimum position and the return air damper will
  open.
• Pass ? Fail ? Retest
• The supply air static pressure sensor will
  modulate the VFD to maintain its set point of
  (___). (This value will be determined by the TAB
  technician.)
• ? Pass ? Fail ? Retest

34

• The discharge air temperature will be maintained
  at ____ by modulating either the chilled water or
  hot water valve to maintain set point.
• Pass ? Fail ? Retest
• Once system is in the normal operating state, the
  minimum outside air CFM will be maintained by the
  pressure differential across the outside air and
  mixed air plenum, the set point will be
  determined by the TAB contractor. (___)
• ? Pass ? Fail ? Retest

35
Record the temperature and humidity after systems
have been in operation for a period no shorter
than 30 minutes
36
While the system is in the normal operation,
verify the following action. Again, all actions
and reactions will be automatic.
Simulate a space temperature increase at ____ of
the ____ VAV terminal units. Verify the system
static pressure is reduced and the static
pressure sensor sends a signal to the VFD to
increase the fan speed to maintain the set point
of _____WG. Record the initial set point, BAS
reading, actual reading, and discharge air
temperature and record the data in the table
below. ? Pass ? Fail ? Retest
37

• Then reset the VAV terminals set points back to
  design. Verify the VDF now ramps down to the
  initial set point.
• Pass ? Fail ? Retest
• At the same time, verify the pressure different
  set point for the mixed air plenum maintains the
  set point of ____. (The mixed air static pressure
  sensor will modulate the return air damper
  position to maintain the mixed air static
  pressure set point (Initial set point of -.20
  IWC, adj. (Set point to be provided by the TAB
  Agency)). The reference point is the outside air
  to the mixed air plenum).
• Pass ? Fail ? Retest
• Record data in the following table.

38
(No Transcript)
39

• Reset the system to normal operation.
• Verify the following occurs. (All operations are
  to be automatic, no intervention from the
  operator.)
• Control of the hot water and chilled water coil
  valves will be energized when the supply fan
  motor is energized. A supply air temperature
  sensor controller input shall modulate the hot
  water and chilled water coil valves as required
  to maintain the supply air temperature set point
  (55 F, adj.). A hot water coil leaving air
  temperature sensor controller input shall
  override the supply air temperature sensor and
  modulate the hot water coil valve as required to
  maintain the coil leaving air temperature above
  the low-limit set point (50 F, adj.).
• ? Pass ? Fail ? Retest

40

• Simulate an increase in space temperature (change
  to discharge air temperature from 55 F to 45
  F), verify the cooling valve opens to maintain
  set point and the hot water valve remains closed.
• ? Pass ? Fail ? Retest
• Simulate a decrease in space temperature (change
  to discharge air temperature from 55 F to 70
  F), verify the cooling valve opens to maintain
  set point and the hot water valve remains closed.
• Pass ? Fail ? Retest
• Simulate a decrease in space relative humidity
  and verify the humidifies energizes to maintain
  set point of ____
• ? Pass ? Fail ? Retest

41
Restore system to normal operation
42
Test Mode Economizer

• Reset or simulate an enthalpy change to index
  system to the economizer mode, verify the outside
  and relief air dampers modulate to provide the
  economizer cycle.
• Pass ? Fail ? Retest
• Restore system to normal operation

43
Test Mode Unoccupied
When the AHU system is indexed to the unoccupied
mode, the supply fan is de-energized. Upon a fall
in any zone air temperature below the unoccupied
set point (55 F, adj.), the supply and return
fans shall start, the outside air and relief
dampers shall remain closed, the return air
damper shall remain open, and the unit and
associated VAVs shall operate in the occupied
mode. When the space temperature rises to the
unoccupied off set point (58 F, adj.), the
supply fan shall be de-energized.
44

• Simulate a time change to index system in to the
  unoccupied mode. Verify the fans shut don and the
  dampers are in the correct position.
• Pass ? Fail ? Retest
• Simulate a temperature increase by setting the
  thermostats on (Quantity) ___ VAVs to full
  cooling. Verify the fans start and the cooling
  valve opens to maintain space temperature.
• Pass ? Fail ? Retest
• Simulate a temperature decrease by setting the
  thermostats on (Quantity) ____ VAVs to full
  heating, verify the fans start and the heating
  valve opens to maintain space temperature.
• ? Pass ? Fail ? Retest

45
Test Mode Morning Warm-Up
Within an hour after system initial startup, the
unit shall be indexed into the warm-up mode or
cool down mode whenever the return air
temperature falls below the warm-up set point,
67 F (adj.), or rises above the cool down set
point (76, adj.). When operating in the warm-up
or cool down, the supply and return fans shall be
started and the outside air damper and relief
damper shall be held closed.
46

• Simulate a time change to index system into the
  morning warm-up mode. Verify the operation of the
  system and dampers.
• Pass ? Fail ? Retest
• During warm-up mode, the outside air and relief
  dampers shall be held closed, the return air
  damper shall be help open, the DAT set point
  shall be raised to (70 F, adj.), and the VAV
  terminal dampers shall modulate in a hot primary
  air state to maintain their individual set
  points. When the return air temperature rises
  above the warm-up off set point (2 F above cool
  down set point, adj.), the unit shall be indexed
  to the occupied mode and the VAV terminal units
  shall be indexed to normal operation with local
  zone sensors regaining control of associated VAV
  terminal units in the cooling state.

47
While system is in the warm-up mode, verify the
VAVs maintain heating set point. Go to ten VAVs
and increase their thermostat set point, verify
the VAV terminal reheat coil modulates to
maintain set point. Record results in the table
below. ? Pass ? Fail ? Retest
48
(No Transcript)
49
Restore System to Normal Operation
50
Test Mode Alarms and Safeties

• Simulate a discharge static pressure above 7.0IWC
  and verify the alarm, trip point pressure, an
  alarm is generated and record in the table below
• Pass ? Fail ? Retest
• Simulate a freeze condition at freezestat and
  verify alarm, trip point pressure, unit shuts
  down, verify the heating and cooling coil valve
  open, coil circulating pumps are energized, an
  alarm is generated, and record the trip
  temperature and record in the table below.
• ? Pass ? Fail ? Retest

51

• Work with the fire authority, verify when the
  smoke detectors are tripped that the system shuts
  down and an alarm is generated.
• Pass ? Fail ? Retest
• Simulate a dirty filter condition and verify an
  alarm is generated and record the trip point in
  the table below.
• ? Pass ? Fail ? Retest

52
(No Transcript)
53
Observations and Comments
54
Sign Off
General Contractor Owner Company
Name Company Name Job Foreman Job
Foreman Mechanical Contractor Electrical
Contractor Company Name Company Name Job
Foreman Job Foreman BAS Contractor Commis
sioning Agency Company Name Company
Name Job Foreman Job Foreman Date Date