Up On The Roof NCBC Up on the roof I've found a paradise that's trouble proof, up on the roof. -C. King/G. Goffin Seattle, Washington

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1 Up On The Roof Up on the roof I've found a paradise that's trouble proof, up on the roof. -C. King/G. Goffin 1962 NCBC 2009 Seattle, Washington June 3, 2009

2 Why Small Packaged HVAC? Buildings < 50,000 square feet: 95% of the buildings 50% of the floorspace Package units cool ~ 45% of the commercial floor space

3 Rooftop Unit World Perfect manufacturer designs Perfect manufacturing Perfect sizing Perfect installation Perfect controls Perfect operation Perfect maintenance

4 CEC-PIER Report RTUs1-4 years Economizers Refrigerant charge Low airflow Cycling fans during occupied period Fans run during unoccupied period Simultaneous heating and cooling No outside air intake at unit Problem Frequency

5 RTU DTU Realities Economizer/OA adjustment: 54% Economizer not working at all: 37% [3 studies report this] Airflow/heat transfer problem: 22% T-stat/controls reset: 32% T-stat replace: 17% Outside air sensor problem: 22% Change over problem: 44% Minimum outside air too high: 20% Minimum outside air too low: 65%

6 RAT-tro Commissioning Photo credit: Totaline, HVACR News 6/26/06 National Building Electricity Use = 76.2% National Buildings With Rats = 63.1% Daunting Challenges to Getting the EE Job Done!

7 O&M Filter

8 1. Reduce fossil fuel use in new buildings by 60% by Reduce fossil fuel use by 60% in an equal amount of renovated buildings by Reduce the target by an additional 10% every 5 years 4. Net zero 2030 [Feds; CA Res -2020]

9 What We Have - PNW 1000 s of RTU 3-15 tons 2nd largest commercial EE measure after lighting Savings are irregularly distributed to say the least Contractors resist refrigerant charge work HVAC contractors; 850 with 10+ employees Active RTU-DTU programs: Puget Sound Energy &?

10 PNW Savings Potential 6 th Northwest Power Plan Estimates Bundle of Measures Analyzed Optimize settings: Cx, economizer, t-stat, coil cleaning 1-stage to 2-stage t-stat OA lockout for electric heat DCV for min vent unoccupied & morning warm up DCV for retail Fleet ventilation strategy with Heat Recovery for new units Electric Savings MWa by 2029 Significant Gas Savings by 2029

11 PNW RTU Research Scope Bench test repair protocols: sensors, economizers, controls (t-stat + economizer), RCA Pilot test & verify protocols-small sample Review existing data sets Develop annualized savings methodology Expanded field measurement-establish savings Draft regional specification for Bonneville Conservation Credit Program

12 Review Existing Data Set 70% had the Honeywell W7459 controller being tested 1% used enthalpy sensors with unknown drift and calibration, although only drybulb sensing is necessary in PNW climate 56% had only a single stage of cooling wired that significantly curtailed economizer use 73% used single changeover point (one outdoor sensor and no return air sensor); 27% used a differential changeover strategy

13 Honeywell DB Sensor Comparison C7650 -old C7660 -new Dry bulb changeover based on A, B C and D setting on economizer module 8 Selectable changeover temperatures 10 degreef dead band 2 degreef dead band 35 F to +100 F (+4 C to +38 C) ambient temp The device remains operational after exposure to extremes of 40 to 125 F (-40 C to 52 C) -40 to 149 F (-40 to 65 C) ambient temp Analog circuit based on C7400 circuit 10 to 20 ma output signal to economizer logic module RTUG Working Group May 2009 Microprocessor based control with +/- 1 degreef accuracy 4 OR 20 ma output signal to economizer control

14 Honeywell C7660 Dry Bulb Sensor Selectable Temperature Options

15 RTU Savings Research Project Concept- Phase 3 RTU Paradigm Shift: from REPAIR toward INTEGRATED RETROFIT Stage 1: repair/service/retrocommissioning protocols: t-stat/controls airflow charge correction if needed economizer belt adjust filter change duct sealing as appropriate opportunistic - depends on tech sophistication RTU Savings Research Project

16 RTU Savings Research Project Concept - Phase 3 RTU Paradigm Shift: from REPAIR toward INTEGRATED RETROFIT Stage 2: Retrofit = bolt on/shovel ready Premium Ventilation Package with integrated controls: Optimum start, strip heat lockout, morning warm up (gas savings), VSD fan control for ventilation air, DCV where appropriate Evaporative assist condenser pre-cooling [drier climates] ECM fan motor or new type motor (i.e.novatorque/proctor Eng Grp) 5-bladed fan [from Florida Solar Energy Center] Outside air sensor placement/housing [EWEB research] Duct redesign/reconstruct FDD with remote communications Other?..TBD

17 RTU Savings Research Project Thesis- Phase 3 RTU Paradigm Shift: from REPAIR toward RETROFIT Business Case, What Business Case?? The business case work for the HVAC contractor for quality/premium service offering =? The business case to customers that service alone results in positive cash flow =? The cost-effectiveness case for utilities or for deeper savings =? Thesis: RETROFIT =VALUE ADDED = making a business case for contractors, customers, and utility ratepayers RTU Savings Research Project

18 Premium Ventilation Package Optimum start Resistance heat lockout Ventilation lockout during morning warm-up with improved damper seals Demand Controlled Ventilation VSD fan control Evaporative condenser pre-cooling [not yet] 42% modeled savings-sacramento

19 CEC PIER Advanced Rooftop Unit (ARTU) Project Goals Address operating problems identified in field research Address performance from an operational/ reliability standpoint rather than efficiency-support install and service quality Work through CEE to approach manufacturers RTUG Working Group May 2009

20 ARTU Desired Outcome Encourage manufacturers to trickle down advanced features to lower-tier models that comprise the majority of the units being installed in California and everywhere else.

21 Economizer (Level 1) Factory-installed economizer Direct-drive modulating actuator, gear driven, permanently lubricated OA and RA dampers bearings. Differential dry-bulb, differential enthalpy or dewpoint/dry-bulb temperature economizer control. Demand controlled ventilation (DCV) control capability. Lock out Compressor when the OAT is lower than SAT. Economizer damper modulates closed if SAT falls below low limit (40 to 45 F). Relief damper located to minimize re-entrainment of exhaust air into OA intake.

22 Economizer (Level 2) Economizer enable/disable deadband no greater than 2 F (dry-bulb temperature control) or 2 Btu/lb (enthalpy control). Relief dampers pressure drop not to exceed XX% of the unit internal pressure drop at 100% relief airflow (percentage to be determined.) Economizer components (sensors, dampers, actuators and controller) warranted for parts and labor by the manufacturer for 2 to 5 years. Improvements in OA and RA dampers to minimize leakage rates.

23 Fans, Unit Efficiency & Refrigeration Cycle Fans Supply fan power limitations as addressed in ASHRAE 90.1 Unit Efficiency CEE 2009 Tier 1 or 2 [exceeds federal max/min] Refrigeration Cycle Level 1: High-efficiency HFC refrigerant with no ozone depletion potential, such as R410a. Level 2: High-efficiency condenser fan motor.

24 Fan Control Fan Control & Refrigeration Control Continuous supply fan operation during occupied hours and intermittent operation during unoccupied hours. During unoccupied hours, supply fan operates for a short period after compressor turns off. Refrigeration Control Adjustable expansion control device such as TXV or EXV.

25 Thermostat A commercial-grade thermostat appropriate for use in commercial buildings. ASHRAE 90.1 Separate heating and cooling setpoints ( dual setpoints) At least 5 F degree deadband Prevent reheating of previously cooled air (except in humidity control applications) Prevent re-cooling of previously heated air Prevent mixing or simultaneously supplying air that has been previously mechanically heated and air that has been previously cooled, either by mechanical cooling or by economizer systems.

26 Thermostat A commercial-grade thermostat (continued) Other Solid state electronic Capable of continuous fan operation during occupied hours Capable of programming time-of-day schedules (night setback / setup) and multiple day types (weekday, weekend) Capable of programming individual holiday schedules Capable of temporary occupied override Capable of two-stage cooling

27 Thermostat Level 1: Thermostat or unit controller incorporates integrated economizer control. Level 2: Thermostat or controller capable of interfacing with an occupancy sensor. Unit switches to intermediate temperature settings when no occupants are present during normally occupied hours.

28 Sensors Sensors for detecting OA and RA conditions shall have the following accuracy: Temperature sensors 1 F. Enthalpy and humidity sensors 5%. CO2 sensors 50 ppm ( ppm range). Enthalpy sensors will have solid state electronic humidity sensing elements. Connectors designed to prevent reversed polarity connections, or, sensors that are not polarity sensitive. For DCV control, CO2 sensor shall be compatible with the controller. (Level 2)

29 Installation & Checkout Capability Labels on the suction, discharge, and liquid lines (for multiple compressors units). A high-pressure refrigerant port located on the liquid line. A low-pressure refrigerant port located on the suction line. Pressure ports accessible from outside of the condenser fan plenum (where compressors located within the condenser fan plenum). Controls to adjust the minimum outside air position accessible with air plenum panels in place. (Level 2)

30 Advanced Monitoring (Level 2) (A) - The following sensors permanently installed to monitor system operation (B) - controller capable of displaying the value of each parameter: Refrigerant suction pressure Refrigerant suction temperature Liquid line pressure Liquid line temperature Outside air temperature Outside air relative humidity Return air temperature Return air relative humidity Supply air temperature Supply air relative humidity.

31 Advanced Monitoring (Level 2) The controller will provide system status by indicating the following conditions: Compressor enabled Economizer enabled Free cooling available Mixed air low limit cycle active Heating enabled Unit controller capable of manually initiating each operating mode (to independently test and verify the operation of compressors, economizers, fans, and heating system).

32 Advanced Diagnostics (Level 2) Controller analog to digital resolution no less than 8 bits. Controller to detect faulty and failed sensors (short or open circuit). Upon detecting a faulty sensor, the controller will send a fault signal to the thermostat and/or energy management system.

33 Advanced Diagnostics (Level 2) Sense a non-operating or improperly operating economizer damper. Send a fault signal upon detection. Diagnostic capability to detect temperature differential across the evaporator coil out of acceptable range. Diagnostic capability to self-monitor refrigerant charge level and detect when the refrigerant charge is outside preset limits.

34 Advanced Diagnostics (Level 2) Controller will diagnose and send a fault signal for the following faults: Severe faults: Failed compressor Failed evaporator fan motor Failed evaporator fan belt Failed condenser fan motor Degradation faults: Dirty air filter Dirty condenser coil Dirty evaporator coil Failed relief damper Air in refrigeration loop Restriction in refrigeration loop

35 SoCalEdison RTU Brainstorm Demand response t-stat with interactive controls Advanced evaporative cooling: straight/indirect/hybrids Evaporative condenser pre-cooling Zone controls Web-based fault detection and diagnostics Climate optimized cooling

36 Package Unit Standard

37 Package unit as received

38 HDAC Package Modifications

39 Package unit blower revisions (not final evaporator coil or coil location)

40 Desert CoolAire Results Sacramento 32 F cooling from the HMX core!

41 Desert CoolAire Results

42 Desert CoolAire Results

43 Through Science There Is Enduring Hope Energy Researchers at Lawrence Berkeley National Laboratory Secure Funding to Breed Glaciers in Captivity Concept from The Onion, Dec 2006 Options for Glacier-Assisted Cooling (GAC) in buildings appear to be easily cost-effective. GAC will also reduce ice machine plug loads in bars and hotels by exojoules/ice cube. -- Senior LBNL Buildings Research Staff

44 New Motor-NovaTorque

45 PNNL & NorthWrite Embedded RTU Diagnostics HVAC HVAC #1 Intelligent Wireless Access Module Receiver for wireless sensor network and transceiver for longdistance wireless telemetry network HVAC #4 Each HVAC unit has a set of sensors connected to an electronics package that includes wireless mesh networking capabilities HVAC #3 HVAC #2 HVAC #6 HVAC #5 ABC Industries

46 FDSI ACRx Sentinel Installation Installed on large Carrier commercial RTU Sentinel modules Cellular site interface, Thermostat and Compressor modules Refrigerant pipe temperature Condensing temperature

47 Web-based Reports KEY PERFORMANCE INDICATOR

Bank of America EMMS System Deployment Key Stats: Single Site 70 Components 4 HVAC Units Avg. 5500 SF 75 man hours Current Status 41% Completed 1,300+ sites 7.

48 Bank of America EMMS System Deployment Key Stats: Single Site 70 Components 4 HVAC Units Avg SF 75 man hours Current Status 41% Completed 1,300+ sites 7.3 MM SF 25 states 93,000 Components 5,300 HVAC Units 98,000 man hours Running 14 Install Teams (24 installers) diversified across 5 contractors Installing at a pace of 5 sites/workday 6 months of consecutive 100+ installs, ramping to 150 Total Scope 3200 Sites 18MM SF 35 States 230,000 Components 13,000+ HVAC Units 250,000+ man hours Version: April 28,

49 EMMS System Operation 49 Version: September, 2008

50 EMMS System Operation Bank HVAC Operations Specialists in Charlotte drive end to end process Version: September,

51 Remote Monitoring Maintenance Vision Generation 1 ic3 Sensors Niagara AX Maintenance Repairs Service Performance Management Capital Equipment Replacement FDSI Insight Data Analytics Niagara AX Remote HVAC Tech FDSI HVAC SAT Remote HVAC Tech FDSI Insight Industry Expertise Version: April 28,

52 Remote Monitoring Maintenance Vision Generation 2 FDSI Inside Niagara AX Maintenance Repairs Service Performance Management Capital Equipment Replacement FDSI Insight System Tuning Niagara AX Remote HVAC Tech FDSI Inside Remote HVAC Tech FDSI Insight Industry Expertise Version: April 28,

53 Expectations and Opportunities Owner Expectations Opportunities Version: April 28,

54 National Cooling Initiative > Market Failures < Consumer Education OEM & 3 rd PartyTechnology Issues Contractor Quality Federal Overlay -Test Protocols/Standards Local Code Compliance & Enforcement Utility Regulatory Policy HVAC Industry Business Model RTUG Working Group May 2009

55 Total US Cooling Solution CTU [Country Top Unit] 50 ZILLON SEER 926

56 BIPV - Brain Integrated Photovoltaics Direct Application, Distributed Generating Resource 100% Market Transformation Potential (net of free riders) HEDR: Human Enabled Demand Response included at no extra cost! BlueEar Receiver Buildings, February 2008

57 "Where there is no vision, the people perish. --Proverbs 21:18 Where there is only vision, the people perish sooner and in larger numbers. --anonymous NBI staff

58 Mark Cherniack ext

HVAC Controls Upgrades: Requirement Details ( )

HVAC Controls Upgrades: Requirement Details ( ) REQUIRED CONTROLS/FEATURES To qualify the upgrade must add or substantially modify 3 or more sequences/system capabilities. Also, all sequences and items listed under the required section are needed in