--SAMPLE--
Air-Cooled Chiller System Functional Test FT___
Functional Test
Project: ____________________________
FT- ____ CHILLER __________
Air Cooled Chiller
And Chiller System Including:
CHW Pumps _____________
Related Tests: _____________________________________________
1.
Participants
Party
Participation
Party filling out this form and witnessing testing ______________________________
Dates of tests ______________________
Dates of tests ______________________
2.
Test Prerequisites
a. __ The following have been started up and startup reports* and prefunctional checklists submitted and
approved ready for functional testing:
Chiller: __Prefuctionals, __Startup report
Chilled water pumps: __Prefuctionals, __Startup report
Chilled water piping and valves: __Prefuctionals
Air handler units: __Prefuctionals, __Startup report
*The written chiller startup report must contain a full listing of all adjustable internal program settings.
b. __ All control system functions for this and all interlocking systems are programmed and operable per
contract documents, including final setpoints and schedules and with debugging, loop tuning and sensor and
device calibrations completed. _________________________________
_________________________
Controls Contractor Signature or Verbal
Date
c. __ Piping system flushing complete and required report approved.
d. __ Water treatment system complete and operational.
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r.
Air-Cooled Chiller System Functional Test FT___
__ Vibration control report approved (if required).
__ Test and balance (TAB) complete and approved for the hydronic system.
__ All A/E punchlist items to date for this equipment corrected.
__ These functional test procedures reviewed and approved by installing contractor.
__ Safeties and operating ranges reviewed.
__ Test requirements and sequences of operation attached.
__ Schedules and setpoints attached.
__ False loading equipment, system and procedures ready (cross-over piping, preheat or reheat coils, control
loops, over-ride on OSA dampers, etc.)
__ Sufficient clearance around equipment for servicing.
__ Sump or crankcase heaters have been on long enough to allow immediate starting of chillers.
__ Have all energy savings control strategies, setpoints and schedules been incorporated that this chiller and
control system are capable of? If not, list recommendations below.
__Misc. tools needed: __two-way radios (general c.), __original calibration temperature probe
(controls c.), pressure gages for evaporator dP (mechanical c.), temperature probe with 6 ft wire or data
logger (commissioner), amp meter for pump amps (commissioner).
__ Control Program Review. Review the software control program(s) for this equipment. Parameters,
setpoints and logic sequences appear to follow the specified written sequences.
__ Record made of All Values for Current Setpoints (SPt), Control Parameters, Limits, Delays, Lockouts,
Schedules, Etc. Changed to Accommodate Testing:
Parameter
Pre-Test
Values
Chiller OSAT lockout
Lead CHW pump ID:
Lag 1 ID:
55F
Returned
to Pre-Test
Values 
Parameter
Pre-Test
Values
Returned
to Pre-Test
Values 
CWRT Setpoint
Safety Overrides or
Jumpers
Delays/Timers
3. Sensor Calibration Checks. The sensors listed below checked for calibration and adequate location.
This is a spot check on a sample of the calibrations done during prefunctional checklisting.*
“In calibration” means making a reading with a calibrated test instrument within 6 inches of the site sensor. Verify that the sensor
reading (via the permanent thermostat, gage or building automation system (BAS)) compared to the test instrument-measured value
is within the tolerances specified in the prefunctional checklist requirements. If not, install offset in BAS, calibrate or replace sensor.
Use the same test instruments as used for the original calibration, if possible.
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Sensor &
Location
Air-Cooled Chiller System Functional Test FT___
Location
OK1
1st
Gage
or
BAS
Value
Final
Gage
Instr.
or
Meas’d BAS
Value
Value
Pass
Y/N?
Chiller
Panel
Value
CHWST
Sensor &
Location
Location
OK1
1st
Gage
Instr.
or
BAS Meas’d
Value Value
Final
Gage
or
BAS
Value
Chiller
Panel
Value
Pass
Y/N?
OSAT
CHWRT
Pump current
(CWP1-CUR)
1
Sensor location is appropriate and away from causes of erratic operation.
*For every sensor originally found out of calibration, check one additional sensor not listed.
4. Device Calibration Checks. The actuators or devices listed below checked for calibration. This is a spot
check on a sample of the calibrations done during prefunctional checklisting and startup.**
“In calibration” means observing a readout in the BAS and going to the actuator or controlled device and verifying that the BAS
reading is correct. For items out of calibration or adjustment, fix now if easy, via an offset in the BAS, or a mechanical fix.
Device or
Actuator &
Location
1st
BAS
Readin
g
Site
Observation
Final
BAS
Reading
Pass
Y/N
Device or
Actuator &
Location
1st
BAS
Reading
Site
Observation
Final
BAS
Reading
Pass
Y/N
**For every actuator or device originally found out of calibration, check one additional one not listed.
5. Verification of Misc. Prefunctional Checks.
Misc. site checks of the prefunctional checklist and startup reports completed successfully. Pass? Y / N _______
1. Verify that in the chiller control panel, Menu 3, that input 30 is enabling a remote chilled water setpoint.
Y/N _________
2. ___All hydronic isolation valves fully open.
3. ___Hydronic balancing valves adjusted per the balance report and permanently marked.
4. ___Pull 3 strainers in strategic locations where debri collection is likely, to verify flush (list):
___All OK?
6. Notes on Methods Used to False Load Chiller (for reference, see Note 6 at end of test)
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
7. General Conditions of Test
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Air-Cooled Chiller System Functional Test FT___
The chiller will be tested with the building in as normal mode as possible. Temperatures are expected to be in the
70’s creating sufficient load for most of the tests. False loading, lowering space setpoints and/or turning on the
preheat will be employed if necessary.
8. Testing Procedures and Record
Proced.
No.
1.
Sequ
Test Procedure3
(including special conditions)
ence.
ID
No.1
2; 3 Startup Sequence
(This is not the initial startup by factory
reps).
a. With chiller system off, with
schedule allowing chillers ON and
OSAT >56F, overwrite the OSAT to be
50F.
b. Return the OSAT to normal
(assuming > 56F), turn chillers and
pumps to auto. Turn ON only one AHU
and command the cooling coil valve
(CCV) to 18% open. A call for the
chillers will be made when any AHU
fan is ON and its CCV is => 15% open
for ____minutes and OSAT is > 55F.
Min. Chiller Flow.
While only 1 CCV is < 20% open and
the other CCV is closed:
2.
3.
2
4.
1; 6
Minimum On-Time
With chiller on and running for less
than 10 minutes [_________],
command all cooling coil valves
closed.
Return CCVs to normal after
procedure.
Lead Pump Start Failure.
Turn chiller OFF. Turn lead pump
(CWP ___) to OFF; turn lag pump
[CWP ____) and chiller to auto. Initiate
a call for cooling per procedure 1.
Expected and Actual Response4
[Write ACTUAL response in brackets or circle]
Pass
Y/N
Note
#
a. Observe that the CHW pump does not
come ON.
b. Observe the lead CHW pump coming ON
after ____ min. [_______]. Observe in the BAS
that the proof of flow has been made (or see it
at the chiller panel). Once there is proof of
flow, observe that the chiller starts.
Observe that the initial CHWST StPt is 49F
[_________] in chiller panel.
Record pump amps [_____] and dP across
pump [_____________] and dP across CHW
evaporator [___________]. Make sure amps
aren’t over the RLA (________) of the pump.
Plot the operating point of the pump on the
pump curve and chiller O&M evap. Dp/gpm
chart to estimate gpm: [curve___________
gpm, chart_____________gpm]. Make sure
the gpm is greater than the minimum req’d
chiller flow of 408 gpm.
Observe that the chiller and pump does NOT
stop until the 10 min. min ON-time is expired.
Observe that after a call for the chiller is made
to the lead pump for 45 seconds[ __________]
an alarm is generated in the BAS [________];
and that the lag pump starts and chiller starts.
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Proced.
No.
5.
Air-Cooled Chiller System Functional Test FT___
Sequ
Test Procedure3
(including special conditions)
ence.
ID
No.1
3, 6, Lead-1 Pump Failure.
++
With chiller having been running in
auto for less than 10 minutes, and all
pumps in auto, turn the operating
pump (CWP_____) to OFF.
6.
1; 6
7.
++
8.
++, 6
9.
3
10.
3
Expected and Actual Response4
[Write ACTUAL response in brackets or circle]
Pass
Y/N
Note
#
Observe that the chiller stops [____________]
and 2 BAS alarms are generated (one for
pump failure and one for chiller low flow), that
the lag pump (CWP_____) starts
[____________] and the chiller restarts after a
timeout period of ________ minutes, having
been manually reset.
Lag Pump Start Failure.
Observe that after a call for the chiller is made
Turn chiller OFF. Assign other pump to to the lead pump for 45 seconds[ __________]
be lead. Turn lead pump (CWP ___) to an alarm is generated in the BAS [________];
OFF; turn lag pump [CWP ____) and
and that the lag pump starts and chiller starts.
chiller to auto. Initiate a call for cooling
per procedure 1.
OSAT Lockout.
Observe the chiller and pumps shut down.
With chiller and pumps in auto and
running, overwrite the OSAT to be 50F
or change the lockout to be 2F above
current OSAT.
Lead-2 Pump Failure.
Observe that the chiller stops [____________]
Change other pump to be the lead
and 2 BAS alarms are generated (one for
pump. With chiller running in auto and pump failure and one for chiller low flow), that
all pumps in auto, turn the operating
the lag pump (CWP_____) starts
(lead) pump (CWP_____) to OFF.
[____________] and the chiller restarts after a
timeout period of ________ minutes, having
been manually reset.
General Chilled Water Temperature
Record the CHWRT [_________] and CHWRT
Control.
setpoint [________].
Have the chiller and pumps in auto for Observe that the 49F [_________] CHWST
less than 10 minutes. Wait for the 10
setpoint in the chiller is released and a new
min. timer to expire.
setpoint [________] is sent to the chiller from
the BAS that will result in bringing the CHWRT
closer to setpoint. (If initial CHWRT is <
setpoint (supposed to be 52F), then the new
CHWST setpoint sent to the chiller should be
> 49 or increasing.
TREND LOG 1. General Chilled Water
Temperature Control
Trend the OSAT, CHWST, CHWRT,
;CHWST setpoint being sent to the
chiller, CHWRT setpoint and both
ASU’s cooling coil valve positions at 2
minute intervals for a 3 day period.
During the trended period, globally
lower the space temperature setpoints
10F for 3 hours to see the chiller go to
full load.
Graph and observe that the chiller maintains
the CHWST setpoint being sent to itXX
and that the CHWRT is maintained at
setpoint.XX
Observe the CHWST setpoint and make sure
that it is not lower than 45F until both CCVs
are > 75% open, otherwise the CHWRT
setpoint may need to be raised from 52F,
XXWithin
+/- 1F during stable periods without
hunting or overshoot (less than +/-3F during
staging, etc.).
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Proced.
No.
11.
12.
Air-Cooled Chiller System Functional Test FT___
Sequ
Test Procedure3
(including special conditions)
ence.
ID
No.1
3
CHWST Hi/Low Alarm
With the chiller and pumps in auto,
overwrite the CHWST to be 39F.
4
Overwrite the CHWST to be 56F.
Return to normal.
Chilled Water Pump Staging.
a. With the chillers and pumps in auto,
command the CCV on both ASUs to
be _______% open, just under where
lag pump will stage ON (orig. seq. was
sum > 100%, but recommend 180%).
b. Command CCVs sum to be just
over pump staging up point.
c. Within 5 minutes, command both
CCVs to be less than ½ of the above
setting % [_________].
13.
14.
4
5
TREND LOG 2. Chilled Water Pump
Staging
Trend each CWP status, each CWP
current, chiller status, both ASU’s CCV
position, OSAT, CHWST, CHWRT at 2
minute intervals for 3 days. Also
datalog or trend an indicator or chiller
load (current, kW, etc.).
During the trended period, globally
lower the space temperature setpoints
10F for 3 hours to see the chiller go to
full load.
Chiller Staging OFF.
With the chiller and pumps in auto,
command the CCVs on both ASUs to
less than 5% open.
Expected and Actual Response4
[Write ACTUAL response in brackets or circle]
Pass
Y/N
Note
#
Observe a BAS alarm [_________].
Observe a BAS alarm [_________].
a. Record pump amps [_____] and dP across
pump [_____________]. Make sure amps
aren’t over the RLA (________) of the pump.
Plot the operating point of the pump on the
pump curve to estimate gpm: [___________
gpm].
b. Observe that the lag CWP does not start
until a 5 min. timer expires.
Record both pump amps [CWP-1_____],
[CWP-2_____] and dP across pumps [CWP-1
_____________, CWP-2 __________] and dP
across evap [_____________]. Make sure
amps aren’t over the RLA (________) of the
pumps. Plot the operating points of the pumps
on the pump curve and evap dp vs gpm chart
to estimate gpm: [curve___________ gpm,
chart ______________gpm].
c.
Observe that the lag pump remains ON
until the 10 min. pump ON timer expires
plus the 5 min. condition timer expires.
Then the lag pump shuts OFF.
Observe that the staging of the pumps is
reasonable and evaluate whether the pumps
stage ON too soon or too late relative to needs
in the building, as shown by the CCV
positions. Note that the chiller or pump are not
ON when OSAT is less than 55F.
Observe that the chiller remains ON until a 5
minute timer expires and the chiller shuts OFF
[_______]. The pump remains ON for another
2 minutes; then it shuts OFF [_________].
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Proced.
No.
15.
16.
Air-Cooled Chiller System Functional Test FT___
Sequ
Test Procedure3
(including special conditions)
ence.
ID
No.1
7
Low ASU Coil Temp. Alarm.
a. Overwrite the OSAT to be 50F. With
the chiller in auto, overwrite ASU-1
discharge temperature to be 34F.
b. Repeat with ASU-2.
--
Return all changed control
parameters and conditions to their
pre-test values5
Expected and Actual Response4
[Write ACTUAL response in brackets or circle]
Pass
Y/N
a.
Note
#
Observe the lead CWP start, but not the
chiller.
b.
Observe the lead CWP start, but not the
chiller.
Check off in table of Section 2 above when
completed
17.
MONITORING AND TREND LOGGING.
Monitoring via BAS trend logs are required per test Procedures 10, 13. Trend logs all shall be provided in
electronic continuous columnar spreadsheet compatible format. Trends all shall be provided in hard tabular format
(continuous columnar with time in left column and at least four columns of point values in adjacent columns). All points
for a given trend will begin at exactly the same time. Provide a key to all abbreviations. Attach representative graphs or
columnar data and explanatory analysis to this test report.
SEQUENCES AND COMPONENTS NOT TESTED
Efficiency rating. Not tested.
Capacity Testing. Not tested.
Misc. Chiller Safeties (part of Trane
startup). Not tested.
NOTES
**Abbreviations: CWP = chilled water pump, Pt = setpoint, CHWS = chilled water supply, BAS = building automation
system, ++ refers to tests being conducted on issues not specifically listed in the sequences of operations provided to
date.
1Sequences
of operation attached to this test.
procedures for manual testing, trend logging or data-logger monitoring.
4Include tolerances for a passing condition. Fill-in spaces or lines not in brackets denote sequence parameters still to be
specified by the A/E, controls contractor or vendor. Write “Via BAS” for verifications of device position from BAS readout
or “Via obs” for actual observation or from test instrument reading.
5Record any permanently changed parameter values and submit changes to Owner.
6 Methods to False Load Chillers
1)
If OSAT is less than 75F, prevent economizer cool OSA from entering the building.
a)
Manually close the economizer OSA dampers, OR
b)
Lower the changeover economizer setpoint below the OSAT (if DB type), OR lastly
c)
Overwrite the OSAT value to be 80F or more so dampers won’t open.
2)
Use OSA preheat coils to heat incoming OSA.
3Step-by-step
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--SAMPLE--
Air-Cooled Chiller System Functional Test FT___
Enable the boiler by removing any lockouts, etc. Manually open the min. OSA preheat coil valve to preheat the
OSA. Increase the min. OSA discharge temperature setpoint and the heating water supply temperature, as
necessary.
3)
Lower the space temperature setpoint.
4)
Prior to the chiller test, manually preheat the building space temperature to 78F - 80F.
5)
Lower the chilled water supply temperature setpoint.
False Loading Cooling Towers
1)
False load the chiller (see above)
A SUMMARY OF DEFICIENCIES IDENTIFIED DURING TESTING IS ATTACHED
-- END OF TEST --
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