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/
Committee Members
2
 Abdullah Ahmed, Sempra
 KC Spivey, PG&E
 Anthony Hernandez, SCE
 Kristin Heinemeier, WCEC
 Brent Eubanks, Taylor Eng.
 Mark Cherniack, NBI
 Chris Scruton, CEC
 Matt Tyler, PECI
 Dale Rossi, FDSI
 Mike Brambley, PNNL
 Dale Gustavson, BBI
 Nathan Taylor, Sempra
 Derek Johnson, Pacific
 Sean Gouw, SCE
Controls
 Dick Lord, Carrier
 Jerine Ahmed, SCE
 Jonathan Douglas, Lennox
 Sherry Hu, PG&E
 Vance Payne, NIST
 Glenn Hourahan, ACCA
 Warren Lupson, AHRI
Gaps
Approaches to Overcome
Tool Availability
3rd Party Tools licensable or acquirable;
OEMs have some capabilities
Analysis shows it is cost effective
Perception of Cost
Faults May Not be
Addressed
Standards Need to be
National
No Method of Test
Data on Incidence
No Defined Levels for
Detection
Research: Understanding Maintenance
Behavior
Reach out to ASHRAE 90.1, 189, 32;
DOE/CBEA
SCE Method of Test, ASHRAE Std.
Method of Test, DOE Method of Test?
Need a research study
Develop levels: ASHRAE Std.
3
>>Agenda
4
9:30
Roll call, review of agenda
9:35
Update on Proposal for Title 24
10:15
Method of Test Development: Acceptance Tests
10:45
Update on National Efforts – ASHRAE, DOE/CBEA
11:15
Demo of FDSI FDD Tool
12:15
Next Steps
12:30
Adjournment
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.
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5
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
HVAC Controls & Economizing
Code 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
6
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
4/8/2011
HVAC Controls & Economizing
Code Change Proposal 5
SECTION 144 – PRESCRIPTIVE REQUIREMENTS FOR SPACE
CONDITIONING SYSTEMS
144 (m) Fault Detection and Diagnostics (FDD) for Packaged DirectExpansion 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.
7
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
4/8/2011
HVAC Controls & Economizing
Code 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
8
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
4/8/2011
HVAC Controls & Economizing
Code 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.
9
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
4/8/2011
HVAC Controls & Economizing
Code Change Proposal 5
NA9.2 – Faults to be Detected
The FDD system shall detect the following faults:
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1.
Air Temperature Sensor Failure/Fault
2.
Low Refrigerant Charge
3.
Economizing When it Should/Shouldn’t
4.
Damper Not Modulating
5.
Excess Outdoor Air
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
4/8/2011
HVAC Controls & Economizing
Summary 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
11
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
4/8/2011
HVAC Controls & Economizing
Summary 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.
12
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
4/8/2011
13
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
Incremental Installed Cost
Incremental Annual Maintenance, 6 tons
PV of Annual Maintenance, 6 tons
Total Incremental Cost, 6 tons
$1,600
($98)
($1,171)
$429
PV of Energy Savings, 6 tons
$2,172
Lifecycle cost savings
$1,743
Benefit/Cost Ratio
CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes
5.1
4/8/2011
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…
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SCE FDD Project Series
 Project 1: Development of an FDD
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



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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
SCE FDD Project Series
Develop FDD Test Method
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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
Near-term Needs
 Establish technical
advisory group
 Draft/review
working test
method
Acceptance Tests/ Certification Tests
 Air Temperature Sensor Failure/ Fault
 Low Refrigerant Charge
 Economizing When it Should/
Shouldn’t
 Damper Not Modulating
 Excess Outdoor Air
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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
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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.
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T24 Proposal
DOE Spec
Notes
Recommendation
Sensor Failure
Sensor Failure/Fault (incl drift)
Suggest DOE remove drift
Air Temp. Sensor Failure/Fault
High Refrigerant Charge
High Refrigerant Charge
Low Refrigerant Charge
Suggest T24 split into two
separate faults
Compressor short cycling
Compressor short cycling
OK
Compressor short cycling
Refrigerant Line Restrictions/TXV
Problems
-
Suggest DOE add Line
Restrictions/TXV Problems
Refrigerant Line Restrictions/ TXV
Problems
Refrigerant Line NonCondensables
-
Suggest DOE add noncondensables
Refrigerant Line NonCondensables
Suggest DOE combine
Low Side HX problem
-
Suggest DOE add High Side HX
problems
High Side HX problem
Capacity Degradation
Suggest T24 add Capacity
Degradation
Capacity Degradation
Efficiency Degradation
Suggest T24 list this as a
degradation fault (but don’t take
double credit for it)
Efficiency Degradation
Not Economizing When it Should
Suggest T24 add Not Economizing
Not Economizing When it Should
Damper Not Modulating
Suggest T24 add Damper not
Modulating
Damper Not Modulating
Excess Outdoor Air
Suggest T24 add Excess Outdoor
Air
Excess Outdoor Air
Low Ventilation
Suggest DOE remove Low
Ventilation
-
High/Low Refrigerant Charge
Low Side HX problem
High Side HX problem
Efficiency Metric for Tracking or
Comparison with No-fault Model
Economizer not Functional or
Optimized
20
Low Evaporator Air Flow
Dirty Filter
Low Refrigerant Charge
Demo of FDSI’s FDD Tool
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>>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)
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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
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kcs7@pge.com