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Onboard/In-Field Fault Detection and Diagnostics

Onboard/In-Field Fault Detection and Diagnostics. a Subcommittee of the Advanced Technology Committee of the Western HVAC Performance Alliance ℠ Subcommittee Meeting 9:30am – 12:30pm (PST) April 18, 2011 Call-in: 712/432-0075 742911# weblink at: http://uc-d.na4.acrobat.com/wcec/ .

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Onboard/In-Field Fault Detection and Diagnostics

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  1. Onboard/In-Field Fault Detection and Diagnostics a Subcommittee of the Advanced Technology Committee of the Western HVAC Performance Alliance℠ Subcommittee Meeting 9:30am – 12:30pm (PST) April 18, 2011 Call-in: 712/432-0075 742911# weblink at: http://uc-d.na4.acrobat.com/wcec/

  2. Committee Members • Abdullah Ahmed, Sempra • Anthony Hernandez, SCE • Brent Eubanks, Taylor Eng. • Chris Scruton, CEC • Dale Rossi, FDSI • Dale Gustavson, BBI • Derek Johnson, Pacific Controls • Dick Lord, Carrier • Jerine Ahmed, SCE • Jonathan Douglas, Lennox • KC Spivey, PG&E • Kristin Heinemeier, WCEC • Mark Cherniack, NBI • Matt Tyler, PECI • Mike Brambley, PNNL • Nathan Taylor, Sempra • Sean Gouw, SCE • Sherry Hu, PG&E • Vance Payne, NIST • Glenn Hourahan, ACCA • Warren Lupson, AHRI

  3. >>Agenda

  4. Proposal for Incorporating FDD in T24 • IOUs (via CASE HMG/PECI) and PIER (via NBI/WCEC) are working together to develop a proposed new requirement. • Informal Workshops held in April and December 2010 • Roundtable on FDD held in July 2010 • Discussion at AFDD Subcommittee in December 2010 • Discussion at AFDD Subcommittee in January 2011 • PIER Report Draft in February 2011 • Discussion at AFDD Subcommittee in March 2011 • PIER Critical Project Review March 2011 • Workshop April 8, 2011 • Workshop April 27, 2011 • Formal “45 day language” workshops in Apr-Jul 2011 •  Adoption March 1, 2012 •  Effective January 1, 2014

  5. HVAC Controls & EconomizingCode Change Proposal 5: FDD • Currently a compliance credit in the performance calculation method • Not required by Title 24 • Credit toward complying with energy budget • Transition to a prescriptive requirement • Not required by Title 24 • Sets the basis of performance standard CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  6. HVAC Controls & EconomizingCode Change Proposal 5 SECTION 144 – PRESCRIPTIVE REQUIREMENTS FOR SPACE CONDITIONING SYSTEMS 144 (m) Fault Detection and Diagnostics (FDD) for Packaged Direct-Expansion Units. All packaged direct-expansion units with mechanical cooling capacity at ARI conditions greater than or equal to 72,000 Btu/hr shall include a Fault Detection and Diagnostics (FDD) system in accordance with NA9 – Fault Detection and Diagnostics. CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  7. HVAC Controls & EconomizingCode Change Proposal 5 Nonresidential Appendix NA9 – 2013 Appendix NA9 – Fault Detection and Diagnostics NA9.1 System Requirements The following sensors should be permanently installed to monitor system operation and the controller should have the capability of displaying the value of each parameter: • Refrigerant Pressure: Suction Line, Liquid Line • Refrigerant Temperature: Suction Line, Liquid Line • Air Relative Humidity: Outside Air, Supply Air • Air Temperature: Outside Air, Supply Air, Return Air CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  8. HVAC Controls & EconomizingCode Change Proposal 5 NA9.1 – System Requirements The controller shall provide system status by indicating the following conditions: • Compressor Enabled • Free Cooling Available • Economizer Enabled • Heating Enabled • Mixed Air Low Limit Cycle Active The unit controller shall manually initiate each operating mode so that the operation of compressors, economizers, fans, and heating system can be independently tested and verified. Faults shall be reported to a fault management application accessible by day-to-day operating or service personnel, or annunciated locally on zone thermostats. A performance indicator shall be provided, which will allow tracking of efficiency. The FDD System used shall be certified by the CEC and verified to be installed correctly. CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  9. HVAC Controls & EconomizingCode Change Proposal 5 NA9.2 – Faults to be Detected The FDD system shall detect the following faults: • Air Temperature Sensor Failure/Fault • Low Refrigerant Charge • Economizing When it Should/Shouldn’t • Damper Not Modulating • Excess Outdoor Air CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  10. HVAC Controls & EconomizingSummary of FDD Products • Currently available fault detection by OEMs (matches NA9.2 Faults to be Detected) • Air temperature sensor failure/fault • Low refrigerant charge • Not economizing when it should • Damper not modulating • Excess outdoor air • Currently available products by third parties • ClimaCheck by ClimaCheck, Inc. • FDSI Synergy by Field Diagnostics, Inc. • Sensus MI, developed by Univ. Nebraska CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  11. HVAC Controls & EconomizingSummary of FDD Products • Third party products currently in development • SMDS by PNNL • Low cost SMDS by PNNL • Low cost NILM by MIT • Virtjoule by Virtjoule, Inc. CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  12. HVAC Controls & Economizing Cost Effectiveness • LCCA for 6-ton RTU • Installed cost for OEM solution is much less than $1600 - this is cost of third party solution w/much longer fault list • Maintenance $ at 50% of expected for conservative estimate • 75% probability of detecting faults with FDD CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

  13. Acceptance Requirements • FDD system installed by HVAC system manufacturer with factory calibration and documented testing • Attach documentation and complete certification statement • Verify that points are mapped correctly within the system • No other functional testing required • FDD system field tested • Functional testing per below…

  14. SCE FDD Project Series • Project 1: Development of an FDD Test Method for Commercial HVAC Packaged Units • Project 2: Development of an FDD Test Method for Residential HVAC Split Systems • Project 3: Laboratory Assessment of Retrofit Fault Detection and Diagnostics Tools on a Commercial HVAC Packaged Rooftop Unit • Project 4: Laboratory Assessment of Retrofit Fault Detection and Diagnostics Tools on a Residential HVAC Split System • Project 5: Evaluating the Effects of Common Faults on a Commercial HVAC Packaged Rooftop Unit • Project 6: Evaluating the Effects of Common Faults on a Residential HVAC Split System Develop FDD Test Method Performance Impacts of Common Faults (Single/Multiple) Choose and assess two highly ranked FDD Tools Comm. 5 Ton RTU Comm. 5 Ton RTU Res. 3 Ton Split Res. 3 Ton Split

  15. SCE FDD Project Series Near-term Needs • Establish technical advisory group • Draft/review working test method Develop FDD Test Method Performance Impacts of Common Faults (Single/Multiple) Choose and assess highly ranked FDD Tools Comm. 5 Ton RTU Comm. 5 Ton RTU Res. 3 Ton Split Res. 3 Ton Split

  16. Acceptance Tests/ Certification Tests • Air Temperature Sensor Failure/ Fault • Low Refrigerant Charge • Economizing When it Should/ Shouldn’t • Damper Not Modulating • Excess Outdoor Air

  17. Update on ASHRAE and DOE/CBEA • Presentation to ASHRAE SSPC 90.1 Mechanical Subcommittee • Presentation to TC 7.5 FDD Subcommittee • Presentation to TC 7.5 • Others to Contact: SPC 189, GPC 32 • CBEA/DOE RTU Spec http://www1.eere.energy.gov/buildings/alliances/rooftop_specification.html

  18. Title: METHOD OF TEST FOR FAULT DETECTION AND DIAGNOSTICS IN UNITARY AIR-CONDITIONING SYSTEMS • Purpose: This standard provides a method of test for the performance of Fault Detection and Diagnostic (FDD) tools on commercial unitary equipment in the laboratory. The objective is to provide a method of test to define an FDD tool’s function. • Scope: 2.1 This standard applies to unitary air conditioning systems. 2. 2 The test is a physical laboratory test on a particular combination of diagnostic tool and make and model of unitary system. 2.3 This standard applies to any on-board, after-market or hand-held functionality that detects and/or diagnoses problems that lead to degraded energy efficiency or capacity, increased maintenance costs, or shortened equipment life. 2.4 This standard provides a method of test to define an FDD tool’s function, not to specify how it should be implemented.

  19. Demo of FDSI’s FDD Tool

  20. >>Next Steps • Working Groups? • Detailed review of HTSDA and related Action Items • Develop strategy and recommendations for action and advocacy for Roadmap integration • Next meeting: Week of May 30 (3-hour webinar)

  21. Thank you! Mark Cherniack markc@newbuildings.org Kristin Heinemeier kheinemeier@ucdavis.edu Jerine Ahmed jerine.ahmed@sce.com Anthony Hernandez anthony.hernandez@sce.com KC Spivey kcs7@pge.com 23

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