Commissioning & Testing Manual - HVAC-Talk

CUSTOMER:

[customer name]

PROJECT:

[project name]

BY:

[DDC Control Company Name]

[ date ]

Building Management System

Commissioning & Testing Manual

Table of Contents

Testing & Commissioning Manual 1. BASE OVERVIEW Page: 1.1 T&C Organization Chart ............................................. 1 1.2 Basewide Network Overview ..................................... 2 1.3 BMS Execution Flowchart .......................................... 3 1.4 DDC Panel Test Flowchart ........................................ 4 1.5 BMS Test Flowchart ................................................... 5 1.6 Basewide I/O Point Summary .................................... 6 2. DDC PANEL/VAV TEST & COMISSIONING Page: 1.1 Electrical-Mechanical Static Test ............................... 1 1.2 Pre-Commissioning Power-Up Test .......................... 2 1.3 DDC Points Test ........................................................ 3 1.4 DDC Panel Functional Test Report ........................... 4 1.5 VAV Functional Test Report ...................................... 5 3. BMS TEST & COMISSIONING Page: 1.1 BMS Network Test ..................................................... 1 1.2 BMS Functional Test Report ...................................... 2 1.3 Final BMS Tests ......................................................... 3 APPENDIX A. Certification of Calibration / Conformance

1.1 T&C Organization Chart 1.2 Basewide Network Overview 1.3 BMS Execution Flowchart 1.4 DDC Panel Test Flowchart 1.5 BMS Test Flowchart 1.6 Basewide I/O Point Summary

1.0 Base Overview

PROJECT: XX-XXX BMS Testing & Commissioning

Organization Chart

[PM Name / Company] Project Manager

[FM Name / Company] Facility Manager

[T&C PM Name / Company] T&C Project Manager

[PE Name / Company] Project Engineer

Site Engrs / Company

Site Engrs / Company

DDC Controllers Commissioning & Testing Flowchart

Electrical – Mechanical Static Test

Pre-Commissioning Power-Up Test

DDC Points Test

DDC Panel Functional

Test Report

VAV Functional

Test Report

BMS Commissioning & Testing Flowchart

BMS Network Test

BMS Functional

Test Reports

Final BMS Tests

1.1 Electrical-Mechanical Static Test 1.2 Pre-Commissioning Power-Up Test 1.3 DDC Points Test 1.4 DDC Panel Functional Test Report 1.5 VAV Functional Test Report

2.0 DDC Panel / VAV Test & Commissioning

Company Name Contractor Name

CONTRACT : ____________ Drawing No. : _____________________

Building : ________________ Panel : _______________________

Level : ________________ Room No. : _____________________

ITEM CHECKED

1 Layout & location of plant match the drawings.

2 No evident mechanical damage to installation.

3 No corroded parts, cleanliness and free from moisture

4 Verify that the manufactures specification is followed.

5 Verify fuse types and rating.

6 Grounding / earthing connection are correct.

7 Cables / equip. are correctly identified and labelled.

8 Location of field devices match the drawings.

9 Location of DDC panel match the drawings.

COMMENTS

Signed ___________________ ___________________

Name ___________________ ___________________

Company [Controls Company] [Witness]

Date ___________________ ___________________

ELECTRICAL-MECHANICAL STATIC TESTBMS SYSTEM

Project Manager Contractor:Client / Project

Project Name

Client Name

Company Name Company Name

CONTRACT : ____________ Drawing No. : _____________________

Building : ________________ Panel : ______________________

Level : ________________

CKT NO.ZONE NO. ROOM NO TYPE OF DEVICE CHECKED

ID-TAGGED

COMMENTS

Signed ___________________ ___________________

Name ___________________ ___________________


Date ___________________ ___________________

PRE-COMMISIONING ELECTRICAL POWER UP TESTBMS SYSTEM

TESTED YES / NO


Project Name

Client Name

Bldg: _________ Level: _________ Panel: _________ AHU: _________

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GENERAL: All control loop parameters, schedules, setpoints, ranges, alarm conditioning statements, and messages will be

readily adjustable at the BAS operator's terminal. All sequences may be overridden manually or by a control sequence of higher authority, such as high static

alarm. The DDC panel user addresses are list after each section of the sequence. AIR HANDLING UNIT AHU-8 START/STOP CONTROL: HAND MODE Switch the Motor Control Panel (MCP) to the ‘Hand’ position. Refer to the plant control wiring diagram and test the hard-wired controls and display, if applicable. START/STOP CONTROL: AUTO MODE The fan system has a software OFF/ON/AUTO point will allow the operator to start or stop the supply fan. OFF – Supply fan will be off 24hrs ON - Supply fan will run 24hrs AUTO – Supply fan will start and stop by the DDC program. Exhaust Fan EF-27 is software interlocked with AHU-8. When the AHU is off the outside air and exhaust air dampers will be closed. Return air damper will be open. The chilled water and hot water control valves will be closed. (AH8_OperCtrl, AH8_SaFanStrStp, AH8_TimeSched) Performed by: Date: Witness by: Date: COLD DECK CONTROL: (Control Strategy - ColdDeck) Cooling will be enabled when the fan status is ON. A PID-loop will modulate the CHW valve to maintain the cold deck temperature at setpoint. The setpoint will be reset by the outside air temperature per the following schedule: OSA Temp Cold Deck Setpoint 70 F 55 F 60 F 65 F (AH8_FanStatus, AH8_ClgVlv, AH8_ColdDeckTemp, AH8_ColdDeckTempSp, AH8_CdRstHiOsa, AH8_CdRstLoOsa, AH8_CdRstHiSp, AH8_CdRstLoSp,) Performed by: Date: Witness by: Date:

DDC Panel Functional Test Report CVAHU with Zone Dampers


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HOT DECK CONTROL: (Control Strategy - HotDeck) Heating will be enabled when the fan status is ON. A PID-loop will modulate the HW valve to maintain the hot deck temperature at setpoint. The setpoint will be reset by the outside air temperature per the following schedule: OSA Temp Hot Deck Setpoint 70 F 75 F 55 F 100 F (AH8_FanStatus, AH8_HtgVlv, AH8_HotDeckTemp, AH8_HotDeckTempSp, AH8_HdRstHiOsa, AH8_HdRstLoOsa, AH8_HdRstHiSp, AH8_HdRstLoSp,) Performed by: Date: Witness by: Date: MIXED AIR TEMPERATURE CONTROL: (Control Strategy - MaTemp) When the economizer is enabled a PID loop will modulate the mixed air dampers to maintain the mixed air temperature at setpoint. (AH8_EconomizerMode, AH8_MaDmpr, AH8_MaTemp, AH8_MaTempSetpt) Performed by: Date: Witness by: Date: ECONOMIZER DAMPER CONTROL: If OA temp is less than RA temp the economizer will be enabled and the mixed air dampers will modulate per the mixed air temperature control. If OSA temp is 1 deg greater than RA temp, the economizer will be disabled and the mixed air dampers will be positioned to minimum OSA and 100% RA. On fan startup, the dampers will be held at O% OSA position for 60 seconds to allow the RA temp sensor to register the correct data. (AH8_EconomizerMode, AH8_OaTemp, AH8_RaTemp, AH8_MinOsaDmpPos) Performed by: Date: Witness by: Date: RETURN AIR CO2 CONTROL: (Control Strategy - MaTemp) The return air CO2 will override all OA damper controls while the fan is running. When the return air CO2 reading approaches the CO2 setpoint (800ppm) the mixed air dampers will be modulated to the outside open position. If the CO2 sensor exceeds 1000ppm an alarm will annunciate on the front end. (AH8_RaCO2, AH8_RaCO2Sp) Performed by: Date: Witness by: Date:


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FAN FAILURE ALARM: When the fan is commanded ON and it does not result in an ON status (2 minute delay on fan startup, 10 second delay after running). (AH8_SaFanStrStp, AH8_SaFanStatus, AH8_FanFailure) Performed by: Date: Witness by: Date: ZONE CONTROL: When the fan is on a PID loop will modulate the zone dampers to maintain the zone space temperature at setpoint. (AH8_SaFanStatus, AH8_Zone1Dmpr, AH8_Zone1RmTemp, AH8_Zone1RmTempSp) Performed by: Date: Witness by: Date:

Bldg: _________ Level: _________ Panel: _________ CH: _________

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CHILLER WATER SYSTEM OVERVIEW: CHILLERS (2) CHILLER WATER PUMPS (2) START/STOP CONTROL: When units AHU-1, AHU-7, FCU-1 or FCU-2 request for cooling (>5% cooling valve position) the lead chiller water pump will be commanded ON. Upon proof of water flow the lead chiller (CH-1) will be commanded ON. Lead/lag operation is based on run hours and space temperature. Should the lead pump fail, the lag pump and lag chiller shall be commanded ON. An alarm condition shall be annunciated. (1080_CH1SS, 1080_CH2SS, 1080_CHWP1SS, 1080_CHWP2SS, 1080_CH1Fail, 1080_CH2Fail, 1080_CHWP1Fail, 1080CHWP2Fail, 1080_CallForCooling, 1080_CHAlwaysOn) Performed by: Date: Witness by: Date: LEAD/LAG: (Control Strategy – CH_LeadLag) When the lead chiller/pump set has 300 hours (adj.) run time logged, the lag set (CH-2) will be designated as lead. Both units shall be rotated equally. Rotation shall not occur during peak operating hours. (1080_CHRunTime) Performed by: Date: Witness by: Date: SUPPLY TEMPERATURE ALARM: When the chiller water supply temperature is above a pre-selected setpoint, an alarm condition shall annunciate and the lag chiller/pump set will be enabled. (1080_CH1CHWSTmpSpt, 1080_CH2CHWSTmpSpt) Performed by: Date: Witness by: Date:

DDC Panel Functional Test Report Chiller Water System

Bldg: _________ Level: _________ AHU: _________

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VAV SYSTEM OVERVIEW: VAV AHU (1) VAV (12)

GENERAL: The appropriate VAV AHU shall be running at static setpoint. Occupied/Unoccupied CONTROL: During occupied hours the VAV boxes shall be commanded to ‘Occupied’ mode. (AHU5_VAVOcc) Performed by: Date: Witness by: Date: ZONE TEMPERATURE: Verify the zone temperature using a temperature meter. Verify correct T-Stat height and location. Verify that the T-Stat is not exposed to false temperatures (ie, Xerox machine, coffee pot, direct sunlight). Performed by: Date: Witness by: Date: DAMPER LEAK: With the AHU running, command the VAV box to ‘Unoccupied’ mode (damper closed). Verify damper leakage per box size and BMS specification. Performed by: Date: Witness by: Date: COOLING-MODE: Modify the zone setpoint 20F below the room temperature. Verify: 1) cooling mode, 2) register discharge temperature, 3) maximum cooling airflow. Performed by: Date: Witness by: Date: HEATING-MODE: Modify the zone setpoint 20F above the room temperature. Verify: 1) heating mode, 2) register discharge temperature, 3) maximum heating airflow. Performed by: Date: Witness by: Date:

Zone Control Functional Test Report VAV System

1.1 BMS Network Test 1.2 BMS Functional Test Report 1.3 Final BMS Tests 1.3.1 BMS Test 1.3.2 PVT Test 1.3.3 Endurance Test

3.0 BMS Test & Commissioning


CONTRACT : ___________ Drawing No. : _____________________

Building : ________________ Panel : ______________________

Level : ________________

ITEM CHECKED INSPECTION DATE COMMENTS

1 Server(s) installed

2 Workstation(s) installed

3 Switches installed

4 BACnet Router installed

5 PAD/BBMD installed

6 Firewall installed

7 Port Forwarding Config.

8 IPSec Site-to-Site VPN

9 Base LAN/WAN comm.

10 Bldg. Network comm.

Additional information & requirements

Signed ___________________ ___________________

Name ___________________ ___________________


Date ___________________ ___________________


Project Name

Client Name

BMS SYSTEMNETWORK TEST


AHU no:

ITEML TEST CHECKLIST YES NO N/A

1 Verify Supply Air Temp.

2 Verify Supply Air Humidity

3 Verify Supply Air Pressure

4 Verify Supply Air Damper OPEN Position

5 Verify Return Air Temp.

6 Verify Return Air Humidity

7 Verify Supply Fan modulation.

8 Verify Cooling Valve modulation.

9 Verify Heater modulation.

10 Verify Supply Temp. Setpoint (default: 55F)

11 Verify Supply Pressure Setpoint (range: 2iwc)

12 Verify Supply Humidity Setpoint (default: 50%)

Performed By: Witnessed by:

AHU BMS FUNCTIONAL TEST

Project Name

PROJECT MANAGER CLIENT / PROJECT CONTRACTOR

Client Name

[Witness Engineer]

[QA/QC Engineer]

Bldg. No:

Room No:

[DDC Control Engineer]


AHU no:

VAV no:

ITEML TEST CHECKLIST YES NO N/A

1 Verify damper modulation.

2 Verify CFM flow.

3 Verify Room Temp.

4 Verify Room Temp Setpoint (default: 74F)

5 Verify Heater modulation.

Performed By: Witnessed by:

VAV BMS FUNCTIONAL TEST

Project Name

PROJECT MANAGER CLIENT / PROJECT CONTRACTOR

Client Name

[Witness Engineer]

[QA/QC Engineer]

Bldg. No:

Room No:

[DDC Controls Engineer]

PROJECT: ___________

1

BMS Test Procedures Test No: BMS-1 Title: System Startup Objective: To demonstrate that the following system startup can initiate the BMS system. Initial Conditions: 1. All BMS equipment is off. 2. The JCI Metasys BMS software and data points are installed into the system. 3. Host Workstation connection to JCI system controller. Event 1. Energize the BMS equipment (Network, DDC controllers). 2. Log in to JCI Metasys BMS (user name/password). 3. Establish a site connection. Expected Result 1. BMS equipment is ready for operation. 2. JCI Metasys system graphics menu appears. Test No: BMS-2 Title: BMS Memory Objective: To demonstrate that the BMS memory can meet the specified maximum capacity of xxx MB. Initial Conditions: 1. Network system controller power switch is on. 2. Host Workstation connection to network system controller. Event 1. Inspect BMS (server/workstation) memory. Expected Results 1. Examine memory: _____MB Test No: BMS-3 Title: BMS Startup and Functions Objective: To demonstrate that the BMS can start operation automatically without human. To demonstrate BMS monitoring and control functions in normal operational mode and in stand-alone mode. Initial Conditions: 1. Network system controller power switch is off. 2. Host Workstation connection to network system controller. Event 1. Power up the network system controller. 2. Verify BMS and DDC communications. 3. Initiate a change in point. Expected Results 1. Verify analog point change by examining the point in Metasys graphics. Test No: BMS-4 Title: BMS Software Validation Objective: To demonstrate that the BMS system contains all system software and disk capacity required in the contract documents to manage the BMS system and associated peripherals as well as supporting command software and application programs. Initial Conditions 1. Host Workstation connection to network system controller Event 1. Using a file manager (ie, Windows Explorer), display the directory of the BMS software. Expected Results 1. View the root file structure for JCI Metasys.

PROJECT: __________

PVT Test Procedures

Test No: PVT-1 Title: BMS and DDC I/O Test Objective: To verify manually activating and deactivating a sample amount of Output points of the BMS network and DDC controller. Initial Conditions 1. Host PC connection to network system controller. Event 1. Modify a Digital Output point. 2. Modify an Analog Output point. Expected Results Verify system I/O change at BMS and at plant. Test No: PVT-2 Title: Operator Commands Objective: To demonstrate that the operator interface with the system for all functions associated with daily operation of the system. Initial Conditions 1. The contractor must provide a list of Operator Commands and an explanation of the expected response. 2. The contractor provides a listing of the I/O points to be addressed during the test. 3. Host Workstation connection to network system controller. Event 1. Log on the system with an incorrect password. 2. Log on the system with a password that allows total operator access to all operator commands. 3. Activate the Help function. 4. Adjust the setpoints of the designated DDC controllers. 5. Modify designated control functions from automatic mode to manual mode. Release back to auto after verification. 6. Override the time schedule of a selected equipment operation. Release back to normal after verification. 7. Modify a point to generate an alarm condition. Restore after verification. 8. Log off the system. 9. Log on to the system with an account that allows minimum operator access to commands. 10. Execute an unauthorized command. Expected Results 1. The system indicates authorization failure and does not allow the operator to log on. 2. System acknowledges User Name and Password. 3. Operator information is presented. 4. Observe system change. 5. Observe system change. 6. Observe schedule change. 7. Verify alarm and acknowledge. Verify normal condition after point restoration. 8. System logs off and requests User Name and Password. 9. Verify limited system access. 10. User is unable to initiate the command.

PROJECT: ________

Endurance Test Procedures The endurance test is to demonstrate the overall reliability of the BMS control system. The endurance test cannot begin until the BMS and PVT tests are complete. 1) All failures and faults found during the BMS and PVT tests must be documented before

the endurance test. All failures and faults should be corrected before the endurance. If, due to logistical or supply reasons, a fault can not be repaired in a timely manner, the fault must be exempt from the endurance test.

2) The endurance will began when the Project Manager (or comparable position) gives

written notice that the BMS and PVT tests are satisfactorily completed. 3) The 1st phase of the endurance test shall be conducted 24 hours per day, 7 days per

week for XX consecutive calendar days. The Contractor shall make no repairs during the 1st phase test unless authorized by the Project Manager in writing.

4) The 2nd phase of the endurance test shall conclude with a written report of operation and

found failures in the 1st phase test. If failures were to occur during the 1st phase test, the report shall explain the nature of each failure (e.g., incomplete software logic), the corrective action taken (e.g., software updated), results of the tests performed and recommend when testing can resume.

5) Based upon the merit of the 2nd phase report the Project Manager may elect to totally or

partially rerun the 1st phase test and elect to require a follow-up 2nd phase report.

Documents

Commissioning & Testing Manual - HVAC-Talk