DRAFT

STANDARD FUNCTIONAL TEST PROCEDURE FOR

HEATING WATER SYSTEMS

BUILDING NAME: APPLICATION #:

BUILDING ADDRESS:

NAME & FIRM OF PERSON(S) DOING TEST:

DATE(S) OF TEST:

General Notes:
1. This is a generic test procedure for heating water systems. It addresses boiler and distribution system performance.
If the complexity, configuration, or other aspects of a specific project require substitute tests or additional tests,
explain on the comments sheets, and attach the additional test procedures and field data. Attach all relevant
functional performance verification sheets, and always attach the final signed and dated procedure certification
page.
2. In all test sections, circle or otherwise highlight any responses that indicate deficiencies (i.e. responses that don’t
meet the criteria for acceptance). Acceptance requires correction and retest of all deficiencies, as defined in each
test section under “Criteria for Acceptance” or “Acceptance”. Attach all retest data sheets. Complete the Deficiency
Report Form for all deficiencies.
3. This Commissioning Procedure does not comprehensively address fire and life safety or basic equipment safety
controls.
4. To ensure that this Commissioning Procedure will not damage any equipment or affect any equipment warranties,
have the equipment manufacturers’ representatives review all test procedures prior to execution.

OPERATOR INTERVIEW (Existing Buildings Only):

Determine from a discussion with the building operator whether the boilers, pumps, and other system equipment are
operating properly to the best of their knowledge. Note any known problems, and possible solutions.

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PREFUNCTIONAL CHECKLISTS:
List all heating water system boilers and pumps and check if the data recorded in the prefunctional checklists has been
reviewed and accepted as accurate.

Part 2 Part 3 Part 4 Part 5 Part 6

Requested Model Verification Installation Checks Operational Checks Sensor Calibration
Documentation Check
Equip. Tag Submitted
Boilers

Pumps

Comments:

DISTRIBUTION SYSTEM DESCRIPTION:

Describe the heating water (HW) distribution system. Address whether the system includes primary and secondary
loop pumps, which pumps are variable volume, whether each primary pump is dedicated to each boiler, whether HW
coil valves are 2-way or 3-way, and so forth. Note if any of the system installed characteristics conflicts with the design
intent or with good design practice.

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FUNCTIONAL PERFORMANCE VERIFICATION:

The following sections are a series of field tests that are intended to verify that the heating water system, as installed,
operates as it was intended to operate by the designer. In general, these tests are best done with the building
unoccupied or lightly occupied. Environmental conditions will be affected. If that is not possible, the commissioning
agent must devise tests that are not intrusive. These will normally involve trending normal operation over a period long
enough to observe the conditions and modes of operation desired.
The following standard tests address the County’s standard control sequences for heating water systems. In general,
these tests presume a constant speed boiler-dedicated primary pump / variable speed secondary pump distribution
system. However, many of the tests are applicable to other circulation and distribution configurations. Use the standard
test procedures where applicable. If more than one boiler or pump can function as the lead under normal (not failed)
operation, then repeat each applicable test with each such unit as the lead unit.
Since there are many possible controls sequences for heating water systems, it is impossible to write generic tests that
cover all such sequences. If the standard test procedures are not applicable or adequate, modify or replace the
standard procedures. Document the sequences, tests, and results at a level of rigor equal to or greater than that of the
standard test procedures. First describe in detail the approved control sequence. Next describe in detail what tests you
plan to do to verify each control sequence, along with any required test conditions. Finally, describe your test results
and conclusions, including any deficiencies found. Add sheets as necessary. It is not necessary to repeat any tests
that were documented in other standard commissioning procedures, but refer to those documents where relevant.
Attach to this form all relevant field data, monitored data, graphs, trend logs, and so forth. Annotate any data and
graphs so that it is clear what the data are proving. EMS trend logs of EMS outputs, program print-outs, or schedule
and setpoint print-outs are not acceptable as proof of operation, unless the information is first verified to be accurate
and documentation is attached. Trend logs of sensor inputs to the EMS are acceptable. If you were not able to
complete a test, explain in a comment.
Full Load Test: (Note: With County’s permission, this test may be omitted.) Perform the following tests and measurements by
forcing each boiler to its maximum capacity. Typically it is best to perform these tests during a near-peak heating day. Any false
loading should be done gradually to avoid overloading systems. Loading can be done by some combination of increasing the
building load (raising heating setpoints), cooling the building, or manipulating the heating water mixing valve on the heating water
return line, as applicable.

BOILER #
1. Leaving boiler heating water (HW) temp, / / /
design / measured

22. Entering boiler HW temp, design / measured / / /

23. Delta (entering - leaving) HW temp, design

24. Delta HW temp, measured. Acceptance:

± 15% of design

25. Boiler water flow rate, design gpm

26. Boiler water flow rate, measured gpm (from

TAB report). Acceptance: ± 10% of design

Notes and Comments:

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Standard Start / Stop Control:

Control Sequence:
1. When any equipment served by the heating water system is on and is (a) calling for heating, or (b) when the
outside air temperature is below setpoint (initial setpoint, 50°F, adjustable), a time counter is started. After 10
minutes (adjustable) of either condition being true, the lead secondary heating water pump if applicable, and then
the lead primary heating water pump (or boiler circulation pump) are started. When boiler flow is proven, the lead
boiler is started.
2. Absence of both of the above start conditions for 15 minutes will cause all heating water system pumps and boilers
to be turned off.
3. When the heating water return temperature (primary, common header, as applicable) is greater than the heating
water supply temperature (primary loop, common header) minus the set differential (initial setpoint, 3 F degrees,
adjustable) for 5 minutes, the lead boiler is turned off. If the OSA temperature is less than setpoint at this time, the
pumps remain on. If the OSA temperature is greater than setpoint, after a time delay of 5 minutes, the lead primary
and secondary HW pumps are turned off.
4. On failure of any lead boiler or pump, the lag unit will operate as the lead.
Functional Performance Tests. (Each test number refers to the respective control sequence number, above.)
1. a) Start of pumps & boilers by coil call for heating.
Sample the HW valves in 2 AHUs and 2 terminal units, or all, whichever is less. Sampled HW valves should include
the largest AHUs in the building. Begin test with equipment in occupied mode, but no HW valves in the building
calling for heating. Change unit or space setpoints such that only one of the sampled valves is calling for heating.
Verify that, after the programmed time delay, the lead pumps start. The lag pumps should remain off. The lead
boiler should start after proof of primary loop flow. Repeat this test for each of the sampled HW valves.
Test Conditions: OSA temperature must be greater than OSA temperature setpoint. Simulation of OSAT or adjustment
of setpoint is acceptable. (Return all setpoints and schedules to original values at conclusion of test.)
Results:
Time and date of observation.
OSAT range and setpoint at time of observation.
Programmed pump start time delay, minutes
Record equipment status HW valve # HW valve # HW valve # HW valve #
(on/off) at beginning of test and _____ Calls for _____ Calls for _____ Calls for _____ Calls for
after time delay + 5 minutes in Heating Heating Heating Heating
column for each HW valve test
Start >5min Start >5min Start >5min Start >5min
HW Pump, lead primary
HW Pump, lag primary
HW Pump, lag-lag primary
HW Pump, lead secondary
HW Pump, lag secondary
HW Pump, lag-lag secondary
Boiler, lead
Boiler, lag
Boiler, lag-lag

Lead boiler starts only after primary pump flow is proven?

Sequence Verified?

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b) Startup of pumps & boilers by OSAT.

Begin test with no HW valves in the building calling for heating, OSAT above setpoint, and system pumps off. Change
OSAT setpoint to 5 F degrees above actual OSAT. Verify that, after the programmed time delay, the lead pumps
start. The lag pumps should remain off. The lead boiler should start after proof of primary loop flow.
Test Conditions: OSA temperature must be greater than setpoint + 5 F degrees at start of test. HW valves throughout
the building must have no call for heating throughout the test. Simulation of temperatures or adjustment of
setpoints is acceptable. All conditions must hold for twice the programmed time delay. (Return all setpoints and
schedules to original values at conclusion of test.)
Results:
Time and date of observation.
Programmed pump start time delay, minutes
No HW valve call for heating?
OSAT and setpoint at start of test.
OSAT and setpoint to trigger pump & boiler start.
Record equipment status
(on/off) at beginning of test & Comments, Deficiencies
after time delay + 5 min.
Start > 5 min.
HW Pump, lead primary
HW Pump, lag primary
HW Pump, lag-lag primary
HW Pump, lead secondary
HW Pump, lag secondary
HW Pump, lag-lag secondary
Boiler, lead
Boiler, lag
Boiler, lag-lag

Lead boiler starts only after primary pump flow is proven?

Sequence Verified?
Notes & Comments:

2. Stop of pumps & boilers by absence of start conditions.

Begin test with any one of sampled HW valves calling for heating, OSAT below setpoint, and system pumps and
boiler(s) on. Change setpoints such that no HW valve is under a call for heating. Verify that, after the programmed
time delay, pumps remain on. Next change the OSAT setpoint to 5 F degrees less than the actual OSAT. Verify
that, after the programmed time delay, all boilers and system pumps are turned off.
Test Conditions: OSA temperature must be less than setpoint - 5 F degrees at start of test. One, and only one, HW
valve must have a call for heating at start of test. Simulation of temperatures or adjustment of setpoints is
acceptable. All conditions, at each of the 2 test stages, must hold for at least 30 minutes. (Return all setpoints and
schedules to original values at conclusion of test.)
Results:
Time and date of observation.
Programmed pump stop time delay, minutes
Which HW valves have call for heating at start of test?
OSAT and setpoint at start of test.
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OSAT and setpoint to trigger pump & boiler stop.

Record clock time and equipment status (on/off) at each condition.
Start no htg call OSAT>setpt
HW Pump, lead primary / / /
HW Pump, lag primary / / /
HW Pump, lag-lag primary / / /
HW Pump, lead secondary / / /
HW Pump, lag secondary / / /
HW Pump, lag-lag secondary / / /
Boiler, lead / / /
Boiler, lag / / /
Boiler, lag-lag / / /
/ / /

Sequence Verified?
Notes & Comments:

3. Stop of pumps & boilers by HW supply/return temperature differential.

Condition 1: Begin with lead boiler on, OSAT less than setpoint - 5 F degrees, and HW return temperature (boiler
return) less than HW supply temperature - differential (3 F deg, adjustable) - 3 F degrees. (So, if HWST=140°F and
the programmed differential is 3 F deg, then the HWRT must be less than 134°F for condition #1.) Expected result:
Lead boiler and lead pumps are on.
Condition 2: Change conditions by changing zone or system setpoints or by commanding HW valves closed such that
the HW return temperature rises above the supply temperature - differential + 1 F degrees at least 5 minutes prior
to the end of the programmed time delay. (So, if HWST=140F and the programmed differential is 3 F deg, then
the HWRT must be greater than 138°F for condition #2.) The OSAT must still be less than setpoint - 5 F degrees.
Expected result: Lead boiler is off and lead pumps are on.
Condition 3: Maintain condition #2 such that the HW return temperature is above the supply temperature - differential +
1 F degrees. If necessary, change the differential to 5 F degrees to facilitate this condition. Change the OSAT
setpoint such that OSAT is greater than setpoint + 5 F degrees. Expected result: All boilers and pumps are off.
Return all setpoints and schedules to original values at conclusion of test.

Results: Record requested information under each condition, and then document equipment status during each
condition in Table 3.1 at the end of this test section.
Condition 1: OSAT less than setpoint - 5 F degrees, and HW return temperature less than HW supply temperature -
differential (3 F deg, adjustable) - 3 F degrees.
Time and date of observation.
Programmed pump stop time delay, minutes
Programmed HW supply / return temperature differential.
Time and date of observation.
OSAT and setpoint (or range) during condition.
HW supply and return temperatures (or range) during condition.

Condition 2: OSAT less than setpoint - 5 F degrees, and HW return temperature greater than HW supply temperature -
differential (3 F deg, adjustable) + 1 F degrees.
Time and date, initial observation / boiler off.
Observed time in minutes until change of equipment status.

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Programmed pump stop time delay, minutes

Programmed HW supply / return temperature differential.
Time and date of observation.
OSAT and setpoint (or range) during condition.
HW supply and return temperatures (or range) during condition.

Condition 3: OSAT greater than setpoint + 5 F degrees, and HW return temperature greater than HW supply
temperature - differential (3 F deg, adjustable) + 1 F degrees.
Time and date, initial observation / pumps off.
Observed time in minutes until change of equipment status.
Programmed pump stop time delay, minutes
Programmed HW supply / return temperature differential.
Time and date of observation.
OSAT and setpoint (or range) during condition.
HW supply and return temperatures (or range) during condition.

Table 3.1
Equipment Status ---> Condition 1 Condition 2 Condition 3 Comments
HW Pump, lead prim.
HW Pump, lag prim.
HW Pump, lag-lag prim.
HW Pump, lead sec.
HW Pump, lag sec.
HW Pump, lag-lag sec.
Boiler, lead
Boiler, lag
Boiler, lag-lag

Sequence Verified?
Notes & Comments:

4. Lead / Lag by Failure of Lead Unit: Turn off the lead unit of each equipment type at the disconnect, and verify that
the lag unit starts and that an alarm is registered at the operator’s terminal. At the conclusion of the test, put all
units back in the auto position at the disconnect. (Note: For dedicated primary pumps, the lead/lag test assumes
that there is an automatic switch to a backup pump. Non-dedicated primary pumps or dedicated pumps with a
manual switch to backup may require a slightly modified test procedure.)
Test Conditions: The building must have a moderate positive heating load. The lead unit of each equipment type must
be operating under normal control at the time it is turned off at the disconnect. The load must be low enough that
the lag units are not operating under normal control. If necessary, change setpoints or command HW valves to
force these conditions.
Results:
If conditions were forced, describe method of forcing.

Boiler, lead at start of test Boiler, new lead after failure of lead
Primary HW pump, lead at start of test Primary HW pump, new lead after failure
Sec. HW pump, lead at start of test Sec. HW pump, new lead after failure
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Sequence verified?
Notes & Comments:

Standard Heating Water Temperature Reset Control:

Control Sequence:
General: The leaving boiler water temperature (primary heating water supply temperature -- PHWST) will be reset as a
function of the highest heating load of selected representative / critical zones. The highest heating load will be
determined by the DDC system highest zone heating load signal, position of the most open heating coil valve, or
similar indicator of true load. Zone temperature by itself is not an indicator of true load. The minimum boiler vessel
temperature will be set at 140°F for non-condensing boilers.
1. The designer, controls contractor, and test and balance contractor will coordinate to identify heating water valves
from representative and critical (but not “wild”) building zones and fan systems. At least 4 such valves from each of
fan systems and zonal reheat coils (or all heating water valves, whichever is less) should be identified.
2. On startup of the boiler, the initial PHWST setpoint will be the midpoint between the upper and lower reset limits.
3. If none of the representative/critical valves are fully open, the PHWST is reset downwards by increments with time
delays between adjustments to allow for system stabilization. The increments and time delays must be tuned for
the specific system, though 5 F degree increments at 10 minute intervals can be used as initial settings.
If one of the representative/critical valves is fully open, no resetting is done.
If two or more of the representative/critical valves are fully open, the PHWST is reset upwards by increments with time
delays between adjustments.
4. The reset table upper and lower limits will be a function of system characteristics. The designer will recommend a
reset schedule. The lower reset limit should be as low as possible, while meeting heating loads, and subject to the
140°F minimum non-condensing boiler vessel temperature . The upper limit should be no higher than required for
coil design loads.

Functional Performance Tests. (Each test number refers to the respective control sequence number, above.)
1. Document the selected representative/critical HW valves. Verify that at least 8 (or all) HW valves have been
selected, and that they are typical of several coils or support critical environmental requirements. Verify by
inspection of the valve signals that none of the valves is “wild” (i.e. usually or always open due to inability to meet
load, forcing the HW reset to the minimum temperature). Such a valve will be considered a deficiency.
Selected Valve (identify Area Served Represen- Critical? Wild?
by AHU, coil, TU, etc.) tative?

Sequence Verified?
Notes & Comments:

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2. Verify that, on lead boiler startup, the initial primary heating water supply temperature setpoint is set at the
midpoint between the upper and lower reset limits. Data for this test can be recorded at the same time as the
system start/stop test, or the lead boiler status and PHWST setpoint can be trended over the startup period at a 1
minute interval.
Results:
Time and date of boiler startup.
Programmed upper and lower PHWST reset limits, deg F.
Primary HW supply temperature setpoint at time of boiler startup.
Sequence Verified?
Notes & Comments:

4. Reset by Valve Position.

Observation 1: Change AHU discharge air setpoints or command HW coil valves such that the lead boiler is on and all
of the representative / critical HW coil valves are less than 70% open. Maintain this state for at least 20 minutes (2
reset periods), and record PHWST setpoint and PHWST at 2 minute intervals. Expected result: PHWST setpoint is
reset downwards the programmed increment at every programmed time delay (approximately 5 F degrees every
10 minutes, or as programmed).
Observation 2: Change AHU discharge air setpoints or command HW coil valves such that all but one of the
representative / critical HW coil valves are at less than 70% open. Cause one of the representative / critical valves
to fully open. Maintain this state for at least 20 minutes (2 reset periods), and record PHWST setpoint and PHWST
at 2 minute intervals. Expected result: PHWST setpoint remains constant.
Observation 3: Change AHU discharge air setpoints or command HW coil valves such that all but two of the
representative / critical HW coil valves are at less than 70% open. Cause two of the representative / critical valves
to fully open. Maintain this state for at least 20 minutes (2 reset periods), and record PHWST setpoint and PHWST
at 2 minute intervals. Expected result: PHWST setpoint is reset upwards the programmed increment at every
programmed time delay.
Test Conditions: The HW return temperature must be greater than the supply +6 F degrees for the duration of this test.
Return all setpoints and schedules to original values at conclusion of test. Trend HW supply and return
temperatures at a 2 minute interval for the period of the three observations. Attach annotated trend logs.

Results:
Time and date of observation.
Programmed reset increment.
Programmed time delay between incremental resets.
HW supply & return temperatures at smallest differential during test.
Time Valve Positions, 3 most PHWST PHWST
open rep./crit. valves Setpoint
/ /
1st Observation: all representative/ / /
critical HW valves < 70% open. / /
/ /
2nd Observation: all but one rep./ / /
critical HW valves <70% open. / /
1 rep/crit valve fully open. / /
/ /
3rd Observation: all but two rep./ / /
critical HW valves <70% open. / /

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2 rep/crit valves fully open. / /

/ /

Notes & Comments.

Sequence Verified?

4. Verify the reasonableness of the PHWST setpoint reset table. Note that this is not so much a test as an
investigation of the parameters that go into defining the reset table.
Data
Highest coil design entering HW temperature
Upper PHWST reset limit.
Acceptance: < highest design ent. HW + 10 F deg
Lower PHWST reset limit.
Acceptance: For non-condensing boilers, >145F or as required to
ensure a boiler vessel temperature > 140°F; For condensing boilers, at
least 40 F deg < upper limit, if adequate to meet loads.

Sequence Verified?
Notes & Comments.

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Standard Boiler Staging Control:

Control Sequence:
1. Multiple boilers (and their respective dedicated primary heating water pumps) will be staged on as a time function
of the secondary loop flow, or variable primary loop flow, as applicable. After the lead, each boiler is to be staged
on when the flow exceeds 95% of the rated maximum flow of the previously staged boiler for 5 minutes. Each
boiler is to be staged off when the flow is less than 90% of the rated maximum flow of the previously staged boiler
for 5 minutes.

Functional Performance Tests. (Each test number refers to the respective control sequence number, above.)
1. a. Set up a table showing which HW valves must be fully open for each of the following flow situations. Note that,
after the lead boiler, each successive flow situation is the sum of the previously staged boiler(s) flow plus the
indicated percentage of the newly staged boiler. The flow in the 2nd and 3rd columns is either the secondary loop
flow or the variable primary loop flow, as applicable.
Operating Boilers Flow % GPM Reqd for HW Valve #s to be GPM of fully open HW
Total Flow opened valves (from TAB report)
Lead boiler #_____ 80%

100%

Lead boiler + 80%

Lag boiler #______

100%

Lead + lag boilers + 80%

Lag-lag boiler #___

100%

80%

100%

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b. Force open the HW valves selected in the above table for each stage by either changing setpoints or manually
commanding them open. Hold each stage for 10 minutes before forcing open the valves required for the next
stage. (The valves from the previous stages will remain open.) Verify that at each stage that the secondary or
variable primary loop flow equals 100% of the currently staged boilers, the next boiler is turned on.
Method used to force valve position:

Operating Boilers Time Record Boiler #s & Comments, Notes, Deficiencies

Primary Pump #s
On
Lead boiler #_____ 80%
100%
Lead boiler + 80%
Lag boiler #______
100%
Lead + lag boilers + 80%
Lag-lag boiler #___
100%
80%
100%

c. Following the above test of staging up, sequentially force closed the HW valves selected in the above table for each
stage by either changing setpoints or manually commanding them closed. Hold each stage for 10 minutes before
forcing closed the valves required for the next stage. (The valves from the previous stages will remain closed.)
Verify that at each stage that the secondary or variable primary loop flow equals 80% of the currently staged
boilers, the most lag boiler is turned off. For dedicated primary pumps, verify that the appropriate primary pump is
turned off with the respective boiler, after a time delay. At conclusion of tests, return all setpoints to original values.
Operating Boilers Time Record Boiler #s & Comments, Notes, Deficiencies
Primary Pump #s
On
Lead + lag boilers + 100%
Lag-lag boiler #___
80%
Lead boiler + 100%
Lag boiler #______
80%
Lead boiler #_____ 100%
80%
100%
80%

Sequence Verified?
Notes & Comments.

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Standard Boiler and Pump Lead / Lag Control:

Control Sequence:
1. If the boiler plant includes two or more boilers of unequal operating efficiencies, the most efficient boiler for the
given conditions will normally be selected as the lead.
2. The operator can command any boiler or pump to the lead and subsequent lag positions.
3. Under automatic control, the DDC system or packaged boiler controls will determine the lead and subsequent lag
boilers based on totalized run time of any unit over the setpoint number of hours (initial setpoint, 100 hours,
adjustable) more than any other unit.
4. For secondary and non-dedicated primary pumps, the DDC system will register an alarm at the operator’s terminal
when the respective lead pump has a totalized run time more than the setpoint number of hours (initial setpoint,
4000 hours, adjustable) more than the lag pump(s). Switching lead and lag pumps will be manual only.

Functional Performance Tests. (Each test number refers to the respective control sequence number, above.)
1. This test is to be completed only if the HW plant contains boilers of more than one model or capacity.
Describe in detail the programmed logic for selecting the most efficient boiler for given conditions.

Does this logic meet the intent of the optimal selection sequence?
Attach annotated trend logs to document that the above-described logic controls lead boiler selection.
Sequence Verified?
Notes & Comments.

2. Trend status of all boilers and primary pumps at a 15 minute interval (or on change of status) for a 3 day period, or
as required to observe all boilers as leads. (It’s only necessary to trend the several hours that encompass normal
startup each day.) At the end of each occupied day, switch the lead, lag, and lag-lag boilers via operator
command. Verify that the commanded unit starts as the lead on the following day during normal startup. Record
observations of start-of-day statuses in the table below.
Test conditions: This test is most conveniently done during the heating season, when boiler startup is reasonably
certain each day. If this condition cannot be met, force boiler startup by changing OSA setpoint, forcing HW valves
open, and/or other means of triggering startup conditions. Do not force boiler startup by direct manual command.
At conclusion of tests, return all setpoints to original values.
Results:
Are primary pumps (boiler circulation pumps) dedicated to specific boilers?
Lead Boiler per Lead Boiler per Lead Primary Comments, Notes,
Operator Trend Log Pump per Deficiencies
Command Trend Log
Day 0 (lead boiler prior NA
to operator command)
Day 1
Day 2
Day 3
Day 4
Day 5
Day 6

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Sequence Verified?
Notes & Comments:

3. Change the adjustable boiler run-time setpoints to the minimum allowable (probably 1 or 2 hours). Allow lead
boilers to run for programmed run-time + 30 minutes. Indirectly force boilers to stop by forcing HW valves closed,
changing setpoints, etc. Do not directly command boilers to stop. Wait 15 minutes, and allow or force conditions
such that lead boiler starts. Observe which boiler and dedicated primary pump starts as lead. At conclusion of
tests, return all setpoints to original values.
Test conditions: This test will disrupt normal HW system operation and can cause comfort complaints. Perform the test
with the building unoccupied or lightly occupied. The test should be performed during the heating season if
possible, so that normal boiler and tower startup is reasonably certain.
Results:
Original boiler run-time setpoints, hours.
Adjusted boiler run-time setpoints, hours.

Time Lead Boiler #, Lead Primary Notes, comments, deficiencies

observed Pump #, observed
Observation 1: initial
condition
Observation 2: run-time +
at least 45 minutes
Observation 3: after
observation #2, run-time +
at least 45 minutes
Observation 4: after
observation #3, run-time +
at least 45 minutes

Sequence Verified?
Notes & Comments:

4. This test applies to secondary and non-dedicated primary HW pumps. Change the adjustable pump alarm run-time
setpoints to 4 hours. (If there is a large discrepancy between accumulated run-times for like service pumps, record
run-times and then zero them out, with County permission.) Allow lead pumps to run for programmed alarm run-
time + 30 minutes. Verify that an alarm is registered at the operator’s terminal and at the Ford Building Insight
station. Verify that pump lead does not switch automatically. At conclusion of tests, return all setpoints to original
values.
Results:
Original pump alarm run-time setpoints, hours.
Adjusted pump alarm run-time setpoints, hours.

Time Lead primary Run-time alarm Lead Run-time alarm

HW pump #, @ terminal / secondary @ terminal /
observed Ford Bldg? HW pump #, Ford Bldg?
observed

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Observation 1: initial / /
condition. Expected result: no
alarms
Observation 2: run-time + at / /
least 30 minutes. Expected
result: alarms but no auto-
switch

Sequence Verified?
Notes & Comments:

Standard Secondary or Variable Volume Primary Heating Water Pump Speed Control:
Control Sequence:
1. All variable volume pumps shall be of identical capacity and head. Each such pump shall be controlled by an
individual VFD. When 2 or more secondary pumps are running, they shall run at the same speed (within ± 1% of
each other).
4. The end-of-run differential pressure setpoint will be determined by the test and balance agency such that the 2–
way valve serving the heating coil with the greatest load is between 90% and 98% open at the same time that the
majority of other heating coils are under a moderate to heavy heating load.
1. The lead pump speed will be modulated between minimum speed (initial setpoint, 20%, adjustable, or minimum
acceptable to motor manufacturer) and an upper staging limit (adjustable), to maintain the end-of-run differential
pressure at setpoint. The upper staging limit is to be selected by the engineer for optimum system wire-to-water
efficiency. Generally, this setpoint will be between 50% and 70% speed, depending on pump capacities, number of
secondary pumps, system head characteristic, etc.
4. If the lead pump is operating at greater than the upper staging setpoint for at least 5 minutes, and the end-of-run
differential pressure is below the setpoint minus an adjustable differential (initial differential, 2 psi), then the lag
pump shall be started and its speed ramped up. Both pumps will run at the same speed, as required to maintain
the end-of-run differential pressure at setpoint.
5. The lag pump is turned off when the end-of-run differential pressure is above the setpoint plus an adjustable
differential (initial differential, 1 psi) for more than 1 minute, and both pumps are running at less than the upper
staging setpoint speed.
6. If the differential pressure is above setpoint plus 2 psi for more than 1 minute, and only the lead pump is running,
and the lead pump is running at minimum speed, then the secondary loop bypass valve will modulate to maintain
the differential pressure at setpoint.

Functional Performance Tests. (Each test number refers to the respective control sequence number, above.)
1. Are all variable volume HW pumps in the same circuit the same capacity and head?
Is each var. volume HW pump driven by its own VFD?
Test Conditions: The building heating load must be high enough that all variable volume HW pumps are running.
Note HW pump speeds (EMS output signal or display at VFD panel) at three different times (with all pumps on), or
attach trend logs of speeds over a period of several hours, and an interval of 15 minutes.
TimePump # ___ Pump # ___ Pump # ___ Pump # ___
Observation 1: ________ __________ __________ __________ __________
Observation 2: ________ __________ __________ __________ __________
Observation 3: ________ __________ __________ __________ __________
Are speeds of all pumps the same ± 1% at each observation?
Sequence verified?

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Notes & Comments:

2. Does the TAB report give evidence that the end-of-run differential pressure setpoint was optimally selected? If not,
comment. Optimal setpoint selection: The 2-way valve serving the heating coil with the greatest load is between
90% and 98% open at the same time that the majority of other heating coils are under a moderate to heavy
heating load (a load roughly equal in magnitude to the design building heating diversity).

3. a. What is the upper staging pump speed limit (% of full speed)?

Review the engineer’s calculations for selection of the upper staging limit setpoint. Do the calculations indicate that the
setpoint was selected for optimum pumping system wire-to-water efficiency? If not, comment.

b. Trend variable volume HW pump speeds and end-of-run differential pressure for 24 hours at a 2 minute interval. If,
upon examination of the trend log, the lead pump speed has not decreased to within 10% of the minimum speed
and increased to within 10% of the upper staging speed limit setpoint (prior to start of lag pump), force HW coil
valves closed and open as necessary to simulate minimum and maximum flows, respectively. (Record maximum
speed at the point when the lag pump is started.) Attach annotated trend logs.
Minimum speed setpoint Upper staging limit setpoint
Identify the lead pump.
Min. lead pump speed during 24 hr trend period
Max. lead pump speed during trend period
If HW coil valves were forced open to achieve minimum and maximum lead pump speeds, describe method of forcing
and record observations for the 2 following questions.

Minimum lead pump speed, HW valves forced closed

Maximum lead pump speed, HW valves #____________ forced open (lead pump only, running)
Sequence verified?
Notes & Comments:

4. Trend variable volume HW pump speeds and end-of-run differential pressure for 24 hours at a 2 minute interval.
This period can coincide with the trend period for test #3, if conditions are such that all variable volume HW pumps
are staged on. If, upon examination of the trend log, all pumps have not staged on, force HW coil valves open as
necessary to stage on all pumps. Attach annotated trend logs.
Identify the lead pump. Identify the lag pump.
Identify the lag-lag pump, if applicable.
Programmed time delay, minutes, for pump stage-on.
Pressure or diff. pressure setpoint Upper differential Lower differential

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Were HW coil valves forced to achieve staging of all pumps? If yes, describe method of forcing.

Record the time, the speed of each running pump, and the end-of-run differential pressure at the time that each
succeeding pump is started (but before the speed ramps up). If the trend log adequately demonstrates this
sequence, attach the annotated trend log in addition to recording in the following table. Expected result: When the
speed of the running pumps reaches the upper staging limit setpoint and the end-of-run differential pressure is less
than the setpoint minus differential and a time delay has elapsed (5 minutes, or as programmed), then, the next
pump is staged on, and all pumps run at the same speed, as necessary to maintain the pressure (DP) at setpoint.
Time End-of-Run Diff. Pump #____ Pump #____ Pump #____
Pressure Speed Speed Speed
Observation 1: lead pump speed <
upper staging limit and DP >
setpoint (- differential)
Observation 2: lead pump speed >
upper staging limit and DP <
setpoint and time of condition >
5 min. Expected: lag pump starts
Observation 3: lead & lag pump
speeds > upper staging limit and DP
< setpoint and time of condition >
5 min. Expected: lag-lag pump
starts

Sequence verified?
Notes & Comments:

5. Trend secondary (or variable volume primary) HW pump speeds and end-of-run differential pressure for 24 hours
at a 2 minute interval. This period can coincide with the trend periods for tests # and/or #4, if conditions are such
that all lag and lag-lag variable volume HW pumps are staged off. If, upon examination of the trend log, all lag
pumps have not staged off, force HW coil valves closed as necessary. Attach annotated trend logs.
Identify the lead pump. Identify the lag pump.
Identify the lag-lag pump, if applicable.
Programmed time delay, minutes, for pump stage-off.
Were HW coil valves forced to achieve staging off of pumps? If yes, describe method of forcing.

Record the time, the speed of each running pump, and the end-of-run differential pressure at the time that each pump
is stopped. If the trend log adequately demonstrates this sequence, attach the annotated trend log in addition to
recording in the following table. Expected result: When the speed of the running pumps decreases to the upper
staging limit setpoint and the pressure is more than the setpoint plus differential and a time delay (1 minute, or as
programmed) has elapsed, then the lag or lag-lag pump is staged off, and all remaining pumps run at the same
speed, as necessary to maintain the pressure (DP) at setpoint.
Time End-of-Run Diff. Pump #____ Pump #____ Pump #____
Pressure Speed Speed Speed
Observation 1: lead, lag, & lag-lag
pump speeds < upper staging limit
and DP > setpoint (+diff.) and time
of condition > 1 min. Expected: lag-
lag pump stops.
Observation 2: lead & lag pump
speeds < upper staging limit and DP
> setpoint and time of condition >
1 min. Expected: lag pump stops.
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Observation 3: lead pump speed <

upper staging limit and DP >
setpoint and time of condition >
1 min. Expected: lead pump
remains on at minimum speed.

Sequence verified?
Notes & Comments:

6. This test can also be verified during the trend periods of tests #3-5. If, upon examination of the trend logs, the lead
pump is never running at minimum speed with the end-of-run differential above setpoint plus differential, force HW
valves closed as necessary to force this condition. Attach annotated trend logs.
Is only the lead pump running?
Lead pump minimum speed observed or trended
Greatest end-of-run differential pressure observed when lead pump is at minimum speed
Programmed time delay, minutes, for bypass valve modulation
Does secondary loop bypass valve modulate open to maintain the pressure below setpoint plus upper differential?

Sequence verified?
Notes & Comments:

I certify that the data and test results as recorded herein are accurate.

Signature, Commissioning Agent Date

Firm Name (Area Code) Phone Number

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