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Component Level Test



System
Component or function to be tested
This form is intended to guide the user through a component level test that is done "on-the-fly" in
the field. In general, it's purpose is to help the user quickly think through the test prior to
executing it. It provides general guidance, a place to outline the proposed test procedure and a
place to document the results. It can be filled out electronically and then printed for use, or the
blank form can be printed out and then filled in by hand. In the electronic version, the second tab
of the workbook contains guidelines for using the form, many of which are linked to the section
they reference. The third tab contains an example of the form filled out for testing a freezestat.
Purpose: Briefly describe the purpose of the test to be performed.




Instructions: Provide instructions regarding how the test results should be documented and what
(if any) follow up actions are necessary.




Equipment Required: Note any special test equipment requirements.




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Component Level Test
Acceptance Criteria: Document the acceptance criteria that will indicate that the test was passed.




Precautions: Document any precautions that need to be taken before, during, or subsequent to the
test.




References: List references like technical papers, CTPL library tests and other information that
might be useful as supporting information for the test team.




Requirement                                                                                      Data               Completed
                                                                                            Include units          Initials, Date
                                                                                                                     and Time
Prerequisites: List any prerequisites that must be in place to execute this test.




Preparation: List steps necessary to prepare for the test.




Procedure: List actual steps in the procedure here.




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Component Level Test




Follow up and Return to Normal: List follow up steps here.




Test Coordinator(s)
Name                               Affiliation                                             Work phone            Work e-mail




Test Team Members
Name                               Affiliation                                             Work phone            Work e-mail




Test Completion Sign Off
This test has been performed to the best of my ability per the requirements of the procedure.
Deviations or problems encountered have been noted at the end of the test form.
Test coordinator name (print)
Signature, date and time


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Component Level Test
Comments and Notes




Comments and Notes

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Component Level Test




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Component Level Test Guidelines


This tab provides guidelines for filling out the component test form. Many of the cells are
electronically linked to the related cells in the blank form.
It is not unusual for a commissioning provider to run into situations where an entire system is not ready
for test, but important components are. For example, shipping or weather induced delays may have
prevented the completion of the piping and control work necessary to allow an air handling system to
fully execute its control sequence per the design intent. However, the Owner or contractor may need to
operate the system in temporary manner to facilitate construction processes. As a result, the
commissioning provider may find themselves involved in discussions of what needs to be done to allow
the system to operate safely in the temporary mode, including any tests that may be necessary to ensure
This form is intended to be operation.
safe and reliable temporary used as a tool to help the provider in such a situation think through the test
process for a system component on the fly in the field, including providing a place to list and verify
important prerequisites, document the steps in the procedure, and document the test results.
Stating the purpose of the test:
Taking a few minutes to develop a statement of the purpose of the test will help you think through what
you are trying to do and firm up the goals of the test. It may also be desirable to state what the
underlying assumptions are. Ideally, the statement should cover why the test is being performed and
what the desired outcome of the test is. This information also allows others working with you during
testing as well as someone reviewing the results to understand what the goals are.

Providing instructions regarding how to document test results:
This section should describe how the results of the test are to be documented including what to do if
something passes or fails. It is important to have a clear statement of how to document things so that the
form provides a clear indication of the test results that can be interpreted reliably by others reviewing
them subsequent to the test.
The form is arranged to document the date and time that each step is executed. Sometimes, the impact
of ripple effects from the test upon other systems or visa-versa is not immediately apparent.
Documenting when, in time, each step occurs, allows the test steps to be correlated with other events
later on.
The form also documents the initials of the person performing the test step. This allows questions that
may come up later to be addressed to the person who is in the best position to remember exactly what
happened by virtue of the fact that they did the work.
Identifying special equipment requirements:
In most instances, test of this type will not require tools or equipment that is not already contained in the
standard toolkit carried by most commissioning providers. But occasionally, a special tool may make
execution of the test easier if it is available. For example a Shortridge® Multimeter with the temperature
probe accessory would be useful for determining, quickly measuring, and documenting multiple
temperature points in a mixed air plenum during a freezestat test, but not mandatory.
Documenting acceptance criteria:
This is an important step because it defines the measured parameters and results necessary to pass the
test. The criteria should tie directly to the goals of the test as stated under Purpose and should be clearly
stated in unambiguous terms.



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Component Level Test Guidelines
Documenting precautions:
Most tests subject the system to some level of risk by design. Sometimes, the risk is an operational risk;
for example, if the test fails, the results may be instability and loss of environmental control in the area
served. This may or may not be a severe risk depending on the nature of the load. For example, in a
Hospital, loosing control of conditions in an operating room would be much more serious than loosing
control of conditions on the loading dock.
In other instances, failure of the test could subject components of the system to damage if not properly
handled. For example, lowering the mixed air temperature in an air handling system towards freezing to
determine if the freezestat trips could result in a frozen coil if the mixing conditions were not adequate or
if careful attention was not paid to the current mixed air condition and the freezestat failed to function.
In addition, it is often necessary to manually shut down some portion of a control process in order to let
another portion be fully tested. For example, testing the freezestat by subjecting it to colder than design
temperatures may required shutting down the mixed air low limit control function and manually
overriding damper commands to force the outdoor air damper open more than would be required under
the current conditions. If automatic damper control and the mixed air low limit process were not re-
enabled subsequent to the test, the system could fail to perform as desired at a minimum and could be
damaged in a worst case scenario.
The precautions section of the test form provides a place to document potential problems and
complications that could occur as the result of the test as well as any measures that should be
implemented to mitigate them. Frequently, they tie in with steps in the preparation and follow-up
portions of the procedure. Taking the time to think through the process and what could go wrong as the
test is developed helps ensure success and minimizes the risk associated with the test process.
Documenting references:
It may be desirable to reference applicable codes and standards, manufacturers data and other
information that provides additional insight into the testing process or requirements or the performance
of the system and component under test. These may be documents referenced by the test writer as the
test is developed. Or, they may be documents that could be useful references to others to whom the test
procedure will be delegated for execution.




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Freezestat Example for Writing a Functional Test
System        Air Handling Unit 1


Component or function to be tested:                                             Freezestat

This form is an example of a component level test for the freezestat of AHU1. The format of this
test can beBriefly describecomponent levelthe test to be performed.
             used for other the purpose of tests by keeping the headings
Purpose: is intended to document the operation of the freezestat on AHU1 and removing the colored
   This test                                                             so that the
    system can be placed in temporary operation to facilitate the finishing of the drywall.
    The test assumes that the manufacturer's factory start-up adequately addresses the
    equipment start-up issues to the extent necessary to ensure that the machinery will not be
    damaged or jeopardized by the temporary operating mode. Several verification checks
    targeted at temporary operation issues have been included in the preparation section
    of the form to ensure that system level issues are addressed before the unit is
    placed in operation.


Instructions: Provide instructions regarding how the test results should be documented and what
     any) each up if the test item passed the
(if Initialfollowstep actions are necessary. test requirements and is completed satisfactorily.
     If the item is not satisfactory or the test step fails, record an "F" in the appropriate box instead of
    your initials. reason for failing in the comments section as a numbered note and include the note
    Document the
    numberthe F on the test form. If the test step has data associated with it, document
    next to
    it on the test form in addition to your initials and the date and time.


Equipment Required: Note any special test equipment requirements.
    Shortridge multimeter with temperature probe for measuring and quickly documenting
    mixed air temperature at multiple points (desirable, but not mandatory).


Acceptance Criteria: Document the acceptance criteria that will indicate that the test was passed.
    1. All prerequisites associated with ensuring safe temporary operation are in place.
    2. The freezestat trips when subjected to air below its set point on any 1 foot segment of
       its element.
    3. The freezestat shuts down the supply and return fans regardless of selector switch




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Freezestat Example for Writing a Functional Test
        positions (hand, auto, inverter, bypass).
    4. The hot water valve goes fully open when the freezestat trips.
    5. Manual reset is required to resume normal operation.


Precautions: Document any precautions that need to be taken before, during, or subsequent to the
test.
   Performing this test will involve subjecting the freezestat to near freezing air by overriding
    the mixed air low limit control system and the outdoor air and return air dampers.
    To prevent damage to the coils, take the following precautions:
    1. Prior to proceeding, spot check the mixing performance of the mixing dampers by
        checking temperatures at various points in the plenum. If there are cold spots, then
        monitor the temperature at those points and ensure that it does not drop below 34°F
        during the course of the test.
    2. Take steps subsequent to the test to:
             a. Ensure that the freezestat set point is returned to normal if adjusted for testing.
             b. Ensure that dampers are returned to automatic control.
             c. Ensure that the mixed air low limit cycle is re-enabled.


References: List references like technical papers, CTPL library tests and other information that
  1. be chapters and 8 of the Functional for the test team.
mightSee useful as2supporting information Testing Guide for Air Handling Systems for
       general testing information (including temporary operation) and information on
      economizer cycles and related functions and controls like mixing,
       mixed air low limit cycles, and freezestats.
    2. See chapter 3 of the Control Design Guide for Air Handling Systems for information


       on the design of safety circuits like freezestats.
    3. See the control shop drawings for the installation and adjustment instructions for
        the freezestat as well as the details of its wiring and the mixed air control system.
       (sheets AH1-1 through 3)


Requirement                                                                                       Data              Completed
                                                                                                                    Initials, Date
                                                                                             Include units            and Time
Prerequisites: List any prerequisites that must be in place to execute this test.
1. Permanent freezestat wiring is in place.
2. Prestart checks and verification checks complete.




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Freezestat Example for Writing a Functional Test
3. AHU and VFD factory start-up complete.
4. MERV13 filters are installed to capture construction dust.
5. Temporary return filters are in place as necessary.
6. Fire/smoke dampers are open as necessary for circulation.
7. Terminal units are open as necessary for circulation.
8. Hot water is available for the heating coil.
9. Mixed air damper controls are in place including a low
    limit cycle and a temporary discharge temperature
    control loop.
10. Outdoor air temperatures are below the normal
     freezestat set point (best) or below the maximum possible freezestat
     freezestat set point.
11. The freezestat is located upstream of all non-preheat coils
     including steam and hot water coils not designed,
     controlled, configured, and piped for preheat service.
Preparation: List steps necessary to prepare for the test.
1. Document the accuracy tolerance for the freezestat from
   the manufacturers literature for future reference.
2. Survey the mixed air plenum at the freezestat element
    location with the unit operating to determine if there are
    any cold spots.
3. If there is more than 15°F of temperature variation
    in the mixed air plenum, do not proceed with the test until
    the mixing performance has been improved. Note that this
     necessitates performing a more detailed analysis of the
     mixed air plenum stratification by documenting
     temperatures at multiple points to assist in correcting
     any mixing problems.
4. Monitor the temperature at the coldest point identified
    above and do not allow this temperature to drop below
    34°F at any time during the test.
5. Manually assume control of the mixing dampers.
6. Document the current out door air temperature. If it is
    below freezing, use extreme caution during the test to
    ensure that subfreezing air is not introduced into the
    system.


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Freezestat Example for Writing a Functional Test
Procedure: List actual steps in the procedure here.
1. Place the hand-off-auto selector switch in the auto
    position and the inverter-bypass switch in inverter.
2. Document the current freezestat set point.
    If at any time during the test, the monitored temperature
    reaches 34°F or drops below the current freezestat
    set point minus the accuracy tolerance, then the test
   failed. Report the results to the appropriate parties for correction.
3. If the outdoor air temperature is below the normal
    freezestat setting use Option 1 below. If it is above it, use Option 2.
Option 1
    a. Gradually force the mixing dampers towards the 100%
        outdoor air position while monitoring the cold spot in
        the mixed air plenum.
    b. Document the temperature at which the freezestat trips.
    c. Verify that:
        i. The hot water valve goes fully open.
        ii. The supply fan shuts down.
        iii. The return fan shuts down.
        iv. The minimum outdoor air damper closes.
        v. The mixing dampers return to 100% recirculation.
        vi. Manual reset is required for normal operation.
    d. Reset the freezestat. Verify that:
        i. The supply fan starts.
        ii. The return fan starts.
        iii. The hot water valve returns to set point control.
        iv. The minimum outdoor air damper opens.
        v. The mixing dampers open.
Option 2
    a. Gradually force the mixing dampers towards the 100%
        outdoor air position while monitoring the cold spot in
        the mixed air plenum.
    b. If the freezestat does not trip, gradually raise the
        freezestat set point up towards the current outdoor
        air temperature while monitoring the mixed air




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Freezestat Example for Writing a Functional Test
        plenum temperature at the cold spot.
    c. Document the temperature at which the freezestat trips.
    d. Verify that:
       i. The freezestat trips at the monitored temperature
             plus or minus the stated accuracy.
        ii. The hot water valve goes fully open.
        iii. The supply fan shuts down.
        iv. The return fan shuts down.
        v. Manual reset is required for normal operation.
    e. Return the freezestat to its normal set point and reset it.
    f. Verify that:
        i. The supply fan starts.
        ii. The return fan starts.
        iii. The hot water valve returns to set point control.
        iv. The minimum outdoor air damper opens.
        v. The mixing dampers open.
4. Repeat the test steps with the h-o-a selector switch in auto.
5. Repeat the test steps with the inverter-bypass switch in
    bypass.
Follow up and Return to Normal: List follow up steps here.
1. Return the freezestat to its normal set point.
2. Return the dampers to full automatic control.
3. Verify that any and all temporary over-rides are removed
    from all alarms and control processes.
4. Note the requirement to test the hot water pump interlock
    with the freezestat at a later date when the pumping
    system is fully operational.
Test Coordinator(s)
Name                               Affiliation                                             Work phone            Work e-mail




Test Team Members
Name                               Affiliation                                             Work phone            Work e-mail




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Freezestat Example for Writing a Functional Test




Test Completion Sign Off
This test has been performed to the best of my ability per the requirements of the procedure.
Deviations or problems encountered have been noted at the end of the test form.
Test coordinator name (print)
Signature, date and time
Comments and Notes




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Freezestat Example for Writing a Functional Test




Comments and Notes




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Freezestat Example for Writing a Functional Test




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