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Functional Performance Test Variable Frequency Drive (VFD) Pump Application

Secondary Hydronic Pump Application
Project: __________________________________ Address: __________________________________ CommissioningParticipants: Commissioningagent(CA): EMSoperator: VFDtechnician: HVACtechnician: Owner'srep.: Date:__________________

_______________________of_____________________ _______________________of_____________________ _______________________of_____________________ _______________________of_____________________ _______________________of_____________________

PumpsID:___________________Chilledwater(CHW)secondary,___Hotwater(HW) Designmax.:Hp:____GPM:______Head_____Ft VFDbrandandmodel:________________________________________________________ ThefollowingfunctionalperformancetestisforaVFDcontrollingavariableflowhydronic systemtoaconstantdifferentialpressure(DP).Acheckmarkdenotesacceptanceor compliance.

I.

Design Intent and Documentation Verification

___ Reviewthedesigndocumentsandthespecifications. ___ VerifythattheVFD___description,___specifications,___technicaland troubleshootingguideandtheinstallation,___programmingrecordand___balance reportareonsite. Fromthedesigndocumentsdetermine:LocationfortheDPmeasurement: _____________________________________________________________________ Controlstrategyforthepump:__________________________________________ _________________________________________________________________________

II.

DifferentialPressureSensor ActuallocationofDPmeasurement____________________________________ Themeasurementshouldideallybetakenacrossthecoilofthelastbranch. ____Complies? Notes:

VFD Installation

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PressureOffset(Po) Conversion:psix2.31=ftH 2O DPpumpisbeingcontrolledto:_______feet[A]. Pressureriseacrosspumpatdesignconditions(frombalancereport):_______feet[B]. Pressureoffset,Po,[A][B]=_______. Optimally,Poshouldbe0.3orlessinorderfortheVFDandpumptobeabletorespond tosmallpressurechangesandrealizeadequateenergysavings.IfPoisgreaterthan0.4, theDPsensorisprobablylocatedtooclosetothepump. ___Complies? BalancingtoLowestPressure ReviewtheHVACbalancereportandverify,accordingtothereport,thatthesystem wasbalancedsotheVFDcontrolstothelowestpossibleDP(thatisacapacitytestwas performed).ThecontrollingDPfrombalancereportsis_________feet.Atdesign,the correspondingVFDfrequencyorpumpRPMfromthebalancereportis:Pump1 ________,Pump2_______;Pump3_____.Thecorrespondingflowfromthebalance reportis_______GPM.Refertothecapacitytestattheendofthisformfordetails. ___BalancedtolowestDP? GeneralIssues ___ Verifythatanypowerqualitymitigationmeasuresrequiredfromthespecificationshave beencompleted. ___ Verifythatthereareno3waycoilvalvesthatmaynegatethevalueoftheVFDby allowingflowtobypassthecoil,exceptforaverysmallmin.flowbypass. ___ VerifyverballythattheaccelerationanddecelerationramptimeoftheVFDisbetween oneandfourminutes.Actualramptime:up_____min.down_____min.(tooshort oframptimeswillresultin"hunting"andexcessmodulationbytheVFD;typicalramp timesare1to4minutes) ___ VerifythateachVFDhasbeenintegratedintotheEMSasperspecification. ___ Verifythatthelowerfrequencylimitisprogrammedto1030%(thelowerthebetter). ___ VerifythattheEMSmonitorstheDP. ___ Min.flowbypasswith2wayorconstantflowvalve,ifpresent,hasflowlessthan2%of designflow? ___ ShutoffpowerfeedingVFD.RestorepowerandverifythatVFDresetsautomatically.

III. Functional Performance Test

Thistestisnotintendedtoverifythatthecoilvalveisfunctioningproperly,butratherthattheVFDis functioningproperly. 1. DesignFlowbyTestandBalance(TAB).RecordinCondition1inTable1thespeed,DP andtotalsupplyflowatdesignconditionsfromtheTABreport.

Notes:

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2.

IntermediateFlow(coilvalvespartiallyopen).Ifcurrentconditionsaresuch,thatthe systemisnotexpectedtobeinfullcoolingorfullheating,norbeatminimumflow. a. Readthespeed,DPandthetotalsupplyflowinthesecondaryloopandrecordin Condition3inTable1. Iftheconditionsarenotinan"intermediate"position,changeallspacetemperatureset pointsto4degreesbelowtheactualtemperatureinthespace,for CHWpumpsOR4 degreesaboveforHWpumps(circleone)tosimulateanapproachingofthermostat satisfactionandtakereadings.

3.

DesignFlow(coilvalvesfullopen).Usingthe(EMS)orothermeans,changeallthespace temperaturesetpointstoatleast10degreesbelowthecurrentspacetemperatureforCHW pumps,OR10degreesaboveforHWpumps,sothattheentireHVACsystemsuppliedfrom thesepumpsisinfullcooling(orheating,asappropriate,circle)inallzones.Observethat allcoilvalvesaretotheirdesignmaximumposition(fromtheTABreport).Waitatleast 20minutesforlagtimewhileobserving:

___Doesthefirstlagpumpturnon(afteradelay)whentheleadpumpexceedsits______ gpmdesignflow? ___Doesthe2ndlagpumpturnon(afteradelay)whenthesumLead+Lag1exceedsthe sumoftheirdesign,ANDtheDPdropsto____%or_____feet?(typically80%) a. 4. Readthespeeds,DPandthetotalsupplyflowandrecordinCondition2.

MinimumFlow(Coilvalvesshut).Changeallspacetemperaturesetpointstobeequalto theactualspacetemperaturestosimulateasatisfiedcondition,drivingtheboxestotheir minimumandthecoilvalvesclosed.Waitatleast25minutes.

___Dothelagpumpssequentiallyturnoff(withadelay)whentheflowislessthanthe designofallrunningpumps? ___Doesthelastpumpshutoffappropriately? a. Takethefrequency,pressureandflowreadingsandrecordinCondition4.

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IV. Analysis
Table 1.
Speed(HzorRPM) Condition 1.AtdesignflowbyTAB Secondary PumpNo. Lead Lag1 Lag2 Lead 2.Atdesignflow(during commissioning) 3.Atintermediateflow (duringcommissioning) 4.Atnoflow(during commissioning) Lag1 Lag2 Lead Lag1 Lag2 Lead Lag1 Lag2 Conversion:0.434xftH2O=psi,2.31xpsi=ftH2O Reading Average DPatSensor(psi) Reading Average Total Flow (gpm)

1. 2.

InTable1,averagethespeedandtheDPforallpumpsateachofthefourconditions. IfthespeedatCondition1(TABtest)isnotwithin10%ofthecurrenttestatCondition2, alltheboxesmaynothavebeendrivenwideopenduringtheCxgtest,orthereadings weretakenbeforethelagtimewascomplete.Investigateandrepeattestsasappropriate. ___Lessthan10%variance? 3. Duringoperationofleadlagpumpcombinations,theaverageDPreadingsatallfour conditionsshouldremainwithin10%ofeachother.Ifthethereismorethana10% variance,thesensormaybefaulty.(Duringleadlagpumptransition,theDPmay appropriatelyvarybyasmuchas20%) ___Lessthan10%variance? 4.___Atnoflow,Condition4,istheflowandDPzeroorequaltothemin.flowbypass? 5.___ForthetotalflowreadingsinTable1,arethevaluesinCondition2>3>4? 6.___CollaborativeTrending Thesystemoperationwill,willnot(circle)betrendedtofurtherverifytheproper operationoftheVFD.PointstobetrendedarelistedintheTrendingRequestForm. ___Fromstudyingthetrends,istheVFDisfunctioningproperly?

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7.

Additionaltests.Refertothechilledwatersystemssequenceofoperationstestsfor furthercollaborationontheVFDperformance.

V. Training

___Thetrainingspecifiedinthedesignincentiveagreementhasbeencompleted.

VI. O&M Plan

___AnacceptableO&MPlanhasbeenputintoplace.Describe:

VII. Capacity Test

Toinsurethatenergyuseisminimized,thehydronicsystemmustbebalancedatdesignconditions atthelowestpossibledifferentialpressure(DP)possible.ThisrequiresthatthelowestpossibleDP atthesensorbefoundthatwillallowthedeliveryofdesignflowthroughthevalvemostdifficultto satisfy.ThissystemminimumDPfoundiswhattheVFDshouldcontrolto.Thisisaccomplished bychangingthetemperaturesetpointforallzonesto55Fforcoolingcoilsor85Fforheatingcoils, causingallAHUcoilvalvestobecallingforfullcoolingorheating,asapplicable.Eachcoilsflow isthenmeasuredagainstthedesignflow.Thecoilthatisreceivingthelowestfractionofdesignis identified.ThecurrentDPatthecontrollingsensorisnoted.Acalculationismade,givingtheDP requiredatthesensortoallowtheidentifiedmostcriticalcoiltomeetitsdesignflow.Theequation isDP2=DP1xQ22/Q12.WhereQ1=actualorfractionofdesignflowduringcapacitytest.Q 2= designflowor1.0ifusingfractions.DP 1=DPatsensor.DP2=DPtocontrolto.Itisnotedthatif allcoilswerecallingforfullcoolingsimultaneously,thepumpcouldnotmaintainthenewDP 2 value,duetodiversitypumpsizereductionhavingbeenmadebythedesignengineer.

Parties required for VFD site commissioning work CommissioningagentTowitnessandrecordthetests. EMSoperatorTodriveboxesopenandshutbychangingthesetpoints,etc. VFDtechnicianTousethekeypadtoverifytheramptime.(unlessverifiedatstartup,whichisrecommended).Sequencing thekeypadtodisplayramptimecouldbedonebythecommissioningagent,aloneafterreviewingtheVFDtechnicalmanual.

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