Test and Balancing

Functional Performance Test Presented by: John Shelander and Dan Acri

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.

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

Modes of Operation

Occupied Economizer Unoccupied Warm-up Alarms and Safeties

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.

Points to consider during planning

Estimated Duration:

Acceptable Results:
Affect on Building Systems: Test Conditions: Staffing: Test Instruments Required:

Staffing

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

Special Test Equipment Required

Instrument
Shortridge Air-Data Meter

Responsible Party
Contractor

Thermometer with both air Contractor and surface probes Two-Way Radios (Minimum of 4 radios) Contractor

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

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

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

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

Verify Fire Alarm System interface is checked

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

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.

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 supplyreturn 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.

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.

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.

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.

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.).

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.

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.

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.

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.

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.

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.

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.).

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.

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.

Functional Performance Test Air Handling Unit 1

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

Record the initial temperatures and humidity

Condition BAS ACTUAL

Outside Dry Bulb Thermometer

Outside Dry Bulb Relative Humidity Space Temperature (Design Set Point) Space Relative Humidity (Design Set Point)

Test Mode:Normal - On

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

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

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

Record the temperature and humidity after systems have been in operation for a period no shorter than 30 minutes
Condition
Outside Dry Bulb Thermometer Outside Dry Bulb Relative Humidity Space Temperature (Design Set Point)

BAS

ACTUAL

Space Relative Humidity (Design Set Point)

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

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.

Static Pressure Table

Set Point BAS ACTUAL Mixed Discharg Air Static e Air Pressure Temp.

Sensor Static Pressure (Normal Operation) Sensor Static Pressure (Full Flow) Sensor Static Pressure (Minimum Flow)

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

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

Restore system to normal operation

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

Test Mode: Unoccupied

When the AHU system is indexed to the unoccupied mode, the supply fan is deenergized. 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.

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

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.

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.

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

VAV Terminal

Design Temp. Setting (F)

Actual Temp. Setting (F)

Simulated Temp. (F)

Heating Valve Opens to Maintain Setting

Pass

Fail

Retest

Restore System to Normal Operation

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

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

Point
Static Pressure High Limit Freezestat

Set Point
7 IWC

Trip Point

Alarm Pass Fail Retest Received

36

Smoke Detector Filter States 1.0IWC

Observations and Comments

Sign Off
General Contractor Company Name Job Foreman Owner Company Name Job Foreman

Mechanical Contractor
Company Name Job Foreman BAS Contractor Company Name

Electrical Contractor
Company Name Job Foreman Commissioning Agency Company Name

Job Foreman
Date

Job Foreman
Date