STANDARD COMMISSIONING PROCEDURE FOR COMMERCIAL REFRIGERATION SYSTEMS

BUILDING NAME: BUILDING ADDRESS: APPLICATION #:

NAME & FIRM OF PERSON(S) DOING TEST: DATE(S) OF TEST: General Notes: 1. This is a generic test procedure for commercial refrigeration systems. Its main emphasis is on energy conserving features of these systems. 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 dont 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 address fire and life safety, refrigerant leak monitoring, or basic equipment safety controls. It also does not address most of the inspections that are typically done during system startup by the refrigeration contractor. 4. To ensure that this Commissioning Procedure will not damage any equipment or affect any equipment warranties, have the equipment manufacturers representative review any interventive test procedures prior to execution. PRE-VERIFICATION INSPECTION: This section is to be completed by the owner or refrigeration contractor prior to calling the Commissioning Agent to the site for testing. Criteria for Acceptance: A No answer to any question in this section indicates that the refrigeration systems are not ready for further commissioning.
INSPECTION ITEM
1. Are all refrigeration equipment, including compressors, condensers, cases, computer control system, etc. on site, operational, and adjusted to final condition? 2. Are all HVAC equipment, including heating and heat recovery coils, VFDs, etc. on site, operational, & adjusted to final condition? 3. Have all refrigerated display cases been fully stocked for at least 2 weeks? 4.

RESPONSE (add sheets as necessary to adequately describe)

CONTACTS (Write name, firm, address, and phone number for each contact): Store Manager, name: address phone Refrigeration Contractor, name: address phone Name of Pre-Verification Inspector: Signature:
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firm:

Firm: Date:
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Building Name: OPERATOR INTERVIEW (Existing Buildings Only): Determine from a discussion with the store manager whether the refrigeration systems are operating properly to the best of their knowledge. Use the table to note any known problems, and possible solutions. NAME OF AFFECTED EQUIPMENT

PROBLEM DESCRIPTION & EFFECT

PROPOSED SOLUTION

ADDITIONAL COMMENTS ON STORE MANGER INTERVIEW:

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Building Name: REFRIGERATION SYSTEMS, INSTALLED CHARACTERISTICS (From field inspection. Note under response if the feature as installed differs in any way from the design documents. If an item does not apply, write NA for not applicable.): Criteria for Acceptance: Installed characteristics must be in accordance with submittals as approved by designer and/or owner.
DESCRIPTION
1. Type of system (uneven parallel, singles, etc.) 2. Compressor type (recip, high efficiency recip, screw, scroll, etc.). Note if any compressors are equipped with variable frequency drives. 3. Number of racks / number of suction circuits. Identify each rack & suction circuit as low, medium, or high temperature. 4. Condenser type (air cooled, water cooled, evaporative) 5. If water cooled condenser, what is the water source (tower, well, etc.)? List the water-side equipment. 6. Is system equipped with computer controls? If so, state manufacturer , model, and systems controlled (refrigeration racks, cases, HVAC, lighting, etc.) 7. Are case anti-condensate heaters automatically controlled? What is the control method (store humidity, door temp, etc.)? 8. Is there heat recovery from the refrigeration compressors to the HVAC system? What is the backup heat source (e.g. gas, electricity)? 9. Is there heat recovery from the refrigeration compressors to the hot water system? What is the backup heat source (e.g. gas, electricity)? 10. Do the systems have floating head pressure control? Are the setpoints less than 80F? If not, explain why. 11. Do the systems have floating suction pressure control? 12. Do rack and case models, capacities, configurations , etc. match the design R/S sheet? Describe any discrepancies. Attach copy of as-installed R/S sheet. 13. Are the case evaporator fans equipped with high efficiency motors? 14. Is there a maintenance log on site? 15. Will refrigeration system maintenance be by contract or by owners staff? 16.

RESPONSE (add sheets as necessary to adequately describe)

COMMENTS ON INSTALLED CHARACTERISTICS ITEMS (add more sheets as needed):

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Building Name: INSTALLATION VERIFICATION: Instructions: Under each unit write "Y" for yes, "N" for no, "NA" for not applicable, or a number to refer to any needed comments. If other information is requested such as temperature, write the appropriate values. Items marked with an u apply only to systems with evaporative condensers. Criteria for Acceptance: All items in this section require answers of Y (or NA, where relevant) except where other criteria are noted.
RACK OR SYSTEM # INSPECTION ITEM
1. 2. 3. 4. Refrigerant type. Acceptance: per submittals. All rack temperature probes are insulated, including discharge temperature sensors All computer control panels are installed and operational Discharge line piping, manifolds, valves, fittings, oil separators, & other accessories are insulated upstream of heat reclaim coils or tank All suction line piping, valves, fittings, manifolds, etc. are insulated Indoor liquid line piping is insulated Anti-sweat heaters are wired to controls, and relays are installed Pump set low for flooded suction. u Water feed system maintains basin water level per mfctrs spec.u

5. 6. 7. 8. 9.

10. No algae or scale build-up.u 11. Water treatment &/or bleed in place. u 12. Freeze protection operable.u 13. 14.

COMMENTS ON INSTALLATION VERIFICATION CHECKLIST ITEMS (add more sheets if needed): ITEM # COMMENT

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Building Name: CONTROLS CALIBRATION:

Controls calibration tests: Perform the following calibration verifications by slowly adjusting the setpoint of each thermostat, humidistat, etc. until the controlled response begins (i.e. contact make or break). Note the setpoint when that occurs, and note the reading on a calibrated thermometer (or other instrument as required) held in close proximity. For sensors, compare the sensor input to the computer refrigeration control system (CRCS) to the field measurement. Check calibration on a sampling of case temperature sensors (approximately 25% of total number of cases), and comment if case temperatures are colder than necessary or warmer than advisable. Use the blank lines for other sensors and stats. Criteria for Acceptance: If sensor or stat is out of calibration by more than 3 degrees F or 5% relative humidity, note that as a deficiency and report it for correction. Note additional acceptance criteria for case temperatures. UNIT #
1. 2. 3. 4. 5. 6. 7. 8. 9. For anti-sweat heater control: Space humidity or dewpoint sensor, setpoint when controlled action occurs, or computer input signal Anti-sweat heater control: Space humidity or dewpoint, measured For HVAC humidity control: Space humidity or dewpoint sensor, setpoint when controlled action occurs, or computer input signal HVAC humidity control: Space humidity or dewpoint, measured Other, stpt @ make/brk or CRCS input (describe point tested): Other, measured: Other, stpt @ make/brk or CRCS input (describe point tested): Other, measured: Other, stpt @ make/brk or CRCS input (describe point tested):

10. Other, measured:

CASE #
42. Case temperature sensor, input to control system (screen value) 43. Case temperature, measured near sensor 44. Is measured case temperature lower than required for product? Acceptance: No more than 10 F deg below minimum product 1 requirement.

CASE #
45. Case temperature sensor, input to control system (screen value) 46. Case temperature, measured near sensor 47. Is measured case temperature lower than required for product? Acceptance: No more than 10 F deg below minimum product 1 requirement.
1

Minimum product requirements as defined in 1994 ASHRAE Refrigeration Handbook, Chapter 31, Table 1.

COMMENTS ON CONTROLS CALIBRATION ITEMS (add more sheets if needed): ITEM # COMMENT

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Building Name: FUNCTIONAL PERFORMANCE VERIFICATION: The following sections are a series of field tests that are intended to verify that the refrigeration systems, as installed, operate as they were intended to operate by the manufacturer and designer. If a test does not apply, write "NA" for not applicable. If you were not able to complete a test, write "ND" for not done, and explain in a comment.
Floating Head Pressure Control: Perform the following tests by monitoring and /or observing each rack or system under actual operation. Use of dataloggers and/or computer refrigeration control system (CRCS) sensor input trending over a period of at least one day is recommended. Annotate any logger and CRCS data and graphs so that it is clear what the data are proving, and attach these to this form. (See attached example of an annotated CRCS graph.) CRCS trend logs of CRCS output signals are not acceptable as proof of operation, unless you have first verified and documented that the output signals accurately represent actual operation. Test Conditions: Perform tests during a period when the outdoor air temperature falls below 60F for at least 4 hours. All recorded measurements should be taken when the cases in the rack in question are not in defrost. Criteria for Acceptance: As noted under specific test items. RACK OR SYSTEM #
1. Record minimum outdoor air dry bulb temperature during testing period (record lowest wet bulb if condenser is water-cooled) Record minimum head pressure setpoint (psig or F). Acceptance: Per approved submittals or 80F, whichever is lower. Record average head pressure coincident to #1. Acceptance: No more than 5 F deg above setpoint as recorded in #2. Record maximum outdoor air temperature during testing period (record highest wet bulb if condenser is water-cooled) Record average head pressure coincident to #4 Does staging of condenser cooling equipment indicate proper functioning of floating head pressure control? Acceptance: Yes

2.

3.

4.

5. 6.

7. 8. 9.

COMMENTS ON FLOATING HEAD PRESSURE TEST ITEMS (add more sheets if needed): ITEM # COMMENT

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Building Name:

Anti-Condensate Heater Control: Complete calibration tests #1 - 2 prior to completing this section. Perform the following tests by monitoring and /or observing the anti-condensate heaters under actual operation. CRCS trend logs of CRCS output signals are not acceptable as proof of operation, unless you have first verified and documented that the output signals accurately represent actual operation. If attached data and graphs sufficiently prove proper operation of the anti-condensate heater controls, it is not necessary to fill in the following table. Criteria for Acceptance: As noted under specific test items. CASE LINE-UP NAME OR #
1. Any symptoms of inadequate heater operation (sweating mullions, fogged glass, etc.)? Acceptance: No If heater control is by single setpoint, record the humidity or dewpoint setpoint. If control is by proportional cycling, skip to item # 6. Record actual space humidity or dewpoint in the vicinity of the sensor. Change setpoint to 2% RH (or 2 F deg dewpt) below the measured space condition. Are the heaters on? Acceptance: Yes Change setpoint to 2% RH (or 2 F deg) above the measured space condition. Are the heaters off? Acceptance: Yes If heater control is by cycling on a reset schedule, record programmed upper setpoint (%RH or deg F dewpoint), and % ON cycle. Record programmed lower setpoint (%RH or deg F dewpoint), and % ON cycle. Measure rel. humidity (or dewpt) near sensor Record CRCS output signal to heaters at time coincident to #8 (% ON cycle). / / / / / /

2.

3. 4.

5.

6.

7. 8. 9.

10. Monitor 2 heater circuits and attach graph, or observe with multimeter whether heaters appear to cycle at same % as #9 (% ON cycle). Acceptance: Graph or other quantitative evidence of proper cycling over at least 50% of control range.

Anti-Condensate Heater Control, if other than one of the 2 strategies in the table above: Criteria for Acceptance: The actual control sequence must be in accordance with submittals as approved by the Designer. Acceptance is based on thorough documented verification of each control mode. Describe the control sequence if other than one of the two strategies in the table above:

Describe the tests that were done to verify the control sequence:

Conclusions:

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Building Name:

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Building Name:
Heat Recovery Control: Perform the following tests by monitoring and /or observing the heat recovery system under actual operation. For tests, slowly increase setpoints such that the heat recovery stages come on sequentially. Lock out any other heat recovery (i.e. lock out HVAC heat recovery when testing hot water heat recovery, and vice-versa). CRCS trend logs of CRCS output signals are not acceptable as proof of operation, unless you have first verified and documented that the output signals accurately represent actual operation. If attached data and graphs sufficiently prove proper operation of the anti-condensate heater controls, it is not necessary to fill in the following table. Criteria for Acceptance: As noted under specific test items. SYSTEM DESCRIPTION / #
HOT WATER HEAT RECOVERY Stage 1, measured values 1. 2. 3. 4. 5. Water temperature entering / leaving Hot gas temp entering / leaving Refrigerant head pressure Condensing temperature Acceptance: The answers to the previous 4 test items must be consistent with efficient heat recovery from compressor discharge gas. / / / / / /

Stage 2, measured values (if applicable) 6. 7. 8. 9. Water temperature entering / leaving Hot gas temp entering / leaving Refrigerant head pressure Condensing temperature / / / / / / / / /

10. Increase the water temperature setpoint by 10 F degrees. Does the backup heat source come on? Was it on prior to the setpoint change, when it should have been locked out? 11. Acceptance: The answers to the previous 5 test items must be consistent with efficient heat recovery from compressor discharge gas.

COMMENTS ON HOT WATER HEAT RECOVERY TEST ITEMS (add more sheets if needed): ITEM # COMMENT

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Building Name:
Heat Recovery Performance Tests, contd. SYSTEM DESCRIPTION / #
HVAC SYSTEM HEAT RECOVERY Stage 1, measured values 1. 2. 3. 4. 5. 6. Air temperature entering / leaving If supply fan is driven by a VFD, record % speed Hot gas temp entering / leaving Refrigerant head pressure Condensing temperature Acceptance: The answers to the previous 5 test items must be consistent with efficient heat recovery from compressor discharge gas. / / / / / /

Stage 2, measured values (if applicable) 7. 8. 9. Air temperature entering / leaving If supply fan is driven by a VFD, record % speed Hot gas temp entering / leaving / / / / / /

10. Refrigerant head pressure 11. Condensing temperature 12. Increase the supply air temperature setpoint by 10 F deg. Does the backup heat source come on? Was it on prior to the setpoint change, when it should have been locked out? 13. Is the minimum head pressure setpoint automatically raised when HVAC heat recovery is called for? Acceptance: If the backup heat source is gas, the minimum head pressure setpoint may not be automatically raised when HVAC heat recovery is called for. 14. Acceptance: The answers to the previous 7 test items must be consistent with efficient heat recovery from compressor discharge gas.

COMMENTS ON HVAC HEAT RECOVERY TEST ITEMS (add more sheets if needed): ITEM # COMMENT

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Building Name: Other Control Sequences (Add additional pages as required): General Instructions: Since there are many possible controls sequences, it is impossible to write generic tests for all such sequences. On this form first describe in detail the controls sequence, then describe what tests were done to verify each, and finally describe your conclusions--including any deficiencies found. Attach to this test sheet all relevant field data, monitored data, graphs, trend logs, etc. Annotate any data and graphs so that it is clear what the data are proving. CRCS trend logs of CRCS outputs, program print-outs, or schedule and setpoint print-outs are not acceptable as proof of operation, though trend logs of sensor inputs to the EMS are acceptable. (Trend logs of CRCS outputs are acceptable if you have first verified and documented that the output signals accurately represent actual operation.) Criteria for Acceptance: The actual control sequence must be in accordance with the design intent documentation and/or approved controls submittal. Acceptance shall be based on thorough documented verification of each control mode. Describe the control sequence:

Describe the tests that were done to verify the control sequence:

Conclusions:

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Building Name:

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

Signature, Commissioning Agent

Date

Firm Name

(Area Code) Phone Number

file:\msoffice\winword\docs\scl\cxproc\refrgqas.pro

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