Functional Testing Guidance

Large Packaged HVAC Systems

This functional testing guidance is designed to aid in developing test procedures for a specific project by describing the
steps involved in testing. The guidance should be adapted as necessary to address the control sequences, configuration,
and performance requirements of the particular system being tested. Additionally, codes may require specific testing
procedures that may not be addressed in this document. All tests based on this guidance should be reviewed carefully to
ensure that they are complete and appropriate.

Test Procedure: Large Packaged HVAC Systems

Overview
The objective of testing a packaged HVAC system is to ensure that each component is working correctly,
and that they all work together as a system to satisfy zone heating, cooling, and ventilation requirements.
Additional objectives of testing are to assess the response to, and recovery from, a power failure, and to
test the interlock with the fire/life safety system. The test guidance outlined below covers both constant
and variable volume units.

System Description
A packaged HVAC system typically includes a wide array of individual components, subsystems, or
related systems, including: supply fan, DX compressor/condenser, heating element (natural gas,
electricity, heat pump, etc.), outdoor and return dampers/actuators, relief dampers, temperature sensors,
and safeties/interlocks. Large package HVAC systems may also include return fans, power relief fans,
volume control devices (such as VFD, inlet vanes, etc.) and additional control sensors
In many respects, a large packaged HVAC system is very similar to a built-up air handling unit and
utilizes many of the same components and control features. The functional test procedures described
below apply to large packaged HVAC systems, which typically have the following characteristics:

All aspects of system operation and control are provided by either an internal microprocessor
controller or a central DDC system.

Outdoor, return, and relief dampers are controlled by individual actuators and are capable of
modulating between fully open and fully closed for economizer operation and to meet minimum
ventilation requirements.

Economizer control strategy is executed through the internal microprocessor controller or central
DDC system. If the economizer is controlled by a stand-alone controller provided by the
manufacturer, then the Small Package HVAC System test guidance should be followed.

DX compressors are staged to meet varying cooling loads. The economizer should be fully integrated
with mechanical cooling.

Return or relief fans (if applicable) can be controlled many ways, including but not limited to, supply
fan tracking, building pressure, or limit switches on the outdoor air dampers (limit switch control is
typically associated with relief fans).

For constant volume systems, heating, economizer, and mechanical cooling control is based on
satisfying space temperature setpoint through the use of a 2-stage thermostat or zone temperature
sensor. For variable air volume systems, heating is generally only used during a morning warm-up
cycle, and the economizer and mechanical cooling are modulated as necessary to maintain discharge
air temperature setpoint.

Sample Test
The following test was not created based on this test guidance but serves as a sample of similar tests. It is
available at www.ftguide.org/ftct/testdir.htm.

Large Packaged Rooftop DX Unit Test. ID#: 302

Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 1 of 9

Functional Testing Guidance

Large Packaged HVAC Systems

Test Procedure Outline

1.

2.

Preparation
1.1

Create a test form

1.2

Determine acceptance criteria

1.3

Provide instructions/precautions

1.4

Specify participants and roles/responsibilities

Large Packaged HVAC System Test Guidance

2.1

Confirm that all system prefunctional checklists are complete

2.2

Verify warm-up operation

2.3

Verify heating operation during occupied hours

2.4

Verify economizer operation during occupied hours

2.5

Verify mechanical cooling operation during occupied hours

2.6

Verify economizer high limit lockout control during unoccupied hours

2.7

Verify system operation during unoccupied hours

2.8. Return system to normal operations

3.

Smoke Control Test Procedures

3.1. Verify system fire shutdown control sequence (if applicable)
3.2. Verify pressurization control sequence
3.3. Verify evacuation control sequence
3.4. Verify smoke purge control sequence

4.

Recovery from Power Failure Test Procedures

4.1. Verify system status when power is lost
4.2. Verify system operation when power is returned

5.

Trending System Operation

5.1. Verify system operation through trending

Preparation
1.1.

Create a test form. Testing will be easier if the test procedure is thought through and
documented before conducting the test. Developing a test form will assist in data collection
and subsequent evaluation, as well as allow less experienced staff to execute the test.

1.2

Determine acceptance criteria. Acceptance criteria are based on design sequence of

operations implemented to control the packaged HVAC system. In general, temperatures

should be maintained within 3F of setpoint without excessive hunting or cycling between
heating and cooling.
1.3

Provide instructions/precautions. If performing the test during subfreezing atmospheric

conditions, ensure proper care is taken to prevent freezing of the coil(s) when verifying
economizer interaction. Be sure to have an emergency exit strategy in place should the test
need to be aborted prior to completion. If a test fails, the source of the failure should be
Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 2 of 9

Functional Testing Guidance

Large Packaged HVAC Systems

identified and conveyed to the proper authority. The system should be retested once the
repairs are complete.
1.4

Specify participants and roles/responsibilities. The testing guidance provided in this

document can assist in verifying proper system performance in both new construction and
existing building applications. At a minimum, the following people should participate in the
testing process. Refer to the Functional Testing Basics section of the Functional Test Guide
for a description of the general role and responsibility of the respective participant throughout
the testing process. The roles and responsibilities should be customized based on actual
project requirements.

New Construction Project

Commissioning Provider
Mechanical Contractor
Control Contractor
Fire/Life Safety Inspector
Electrical Contractor

Existing Building Project

Commissioning Provider
Building Operating Staff
Controls Contractor
Fire/Life Safety Inspector

2. Large Packaged HVAC System Test Guidance

2.1

Confirm that all system prefunctional checklists are complete. Prior to performing any

functional tests, the commissioning pre-start, start-up, and verification checklists should be
completed, as well as applicable manufacturer's pre-start and start-up recommendations.
Prefunctional checklist items include, but are not limited to, the following:
2.1.1

Supply fan spins in the right direction and is free of unusual noise and vibration.

2.1.2

Supply fan belt tension, alignment, and condition are OK (if applicable).

2.1.3

Return and/or powered relief fan spins in the right direction and is free of unusual
noise and vibration (if applicable).

2.1.4

Return and/or powered relief fan belt tension, alignment, and condition are OK (if
applicable).

2.1.5

Outdoor, return, and relief dampers stroke freely with minimum play.

2.1.6

Damper assemblies are clean of any construction debris, dirt, or other foreign
materials.

2.1.7

Evaporator coil is clean and fins are in good condition.

2.1.8

Condensate trap/drain is piped per manufacturers specification.

2.1.9

Compressor(s) has no unusual noise or vibration.

2.1.10 Condenser coil is clean and fins are in good condition.

2.1.11 There is adequate clearance around condenser for proper air flow.
2.1.12 All field-mounted sensors are installed per manufacturers specification and
calibrated (either field calibration or calibration certificates).
2.1.13 All safeties and interlocks are functional (i.e. freezestat, compressor lockout, static
pressure limit switches, etc.).
2.1.14 Appropriate occupied, unoccupied, and holiday schedules are programmed in the
DDC system or microprocessor.

Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 3 of 9

Functional Testing Guidance

2.2

Large Packaged HVAC Systems

Verify warm-up operation. Most variable air volume and some constant volume units may

utilize a warm-up sequence to bring a space up to temperature prior to occupancy. The

control strategy is generally based on satisfying a return air temperature setpoint. Note that
excessive leaks in the building envelope may allow outdoor air to infiltrate the return air
plenum (if applicable), which can have an adverse impact on the warm-up cycle control. In
order to test the control sequence, simulate an unoccupied condition by either setting the
schedule in the DDC system or microprocessor to include the actual time the test is being
performed or adjusting the time to be within the unoccupied schedule and adjusting the
warm-up setpoint(s) as necessary to trigger the warm-up cycle.
Check the following:

2.3

2.2.1

Supply fan (and return fan if applicable) is operating.

2.2.2

Outdoor and relief air dampers are fully closed.

2.2.3

Return air damper is wide open.

2.2.4

Power relief fans (if applicable) are not operating.

2.2.5

DX compressor and condenser are not enabled.

2.2.6

Heating is enabled and staged as necessary to satisfy control setpoint.

2.2.7

Allow unit to enter an occupied mode while still in warm-up mode. Verify that
heating terminates when the warm-up setpoint is achieved and that the unit does not
go back into warm-up mode.

Verify heating operation during occupied hours. Constant volume systems generally

stage heating elements as necessary to maintain space temperature setpoint, but many
variable air volume (VAV) systems do not have a heating mode other than morning warm-up.
Heating for a packaged VAV system is generally provided by reheat coils in the terminal units
that serve their respective zones. However, the unit may have an occupied heating mode
option that must be selected in order to enable the control strategy.
Simulate an occupied condition by either setting occupancy schedule in the DDC system or
microprocessor to include actual time the test is being performed or adjusting the time to be
within the occupied schedule. Raise either the space temperature setpoint or heating
temperature setpoint (if occupied heating mode in a VAV unit is selected) to be 10F above
current ambient conditions in order to generate a call for heating.
Check the following:
2.3.1

Supply fan (and return fan if applicable) is operating.

2.3.2

Outdoor air damper is at minimum ventilation position. Minimum position should be

set based on the measured outdoor air flow rate meeting design.

2.3.3

Relief fan (if applicable) should not be operating.

2.3.4

DX compressor and condenser are not enabled.

2.3.5

Heating is enabled. Note of precaution raising space temperature above ambient

conditions may have adverse impact on workers or equipment located in the zone
being tested.

2.4. Verify economizer operation during occupied hours. The economizer will typically be
the first stage of cooling in both constant and variable air volume systems. Some constant
volume units are controlled by a zone thermostat, which will simply enable the economizer
when the Y1 circuit is energized (first stage call for cooling) and outdoor air conditions are
adequate to economize. Other constant volume systems may modulate the economizer as
necessary to meet a discharge air temperature setpoint if space temperature exceeds cooling
Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 4 of 9

Functional Testing Guidance

Large Packaged HVAC Systems

setpoint. Most variable air volume systems typically control cooling operation by
maintaining a discharge air temperature setpoint as space temperature deviates from the
cooling temperature setpoint.
Leave the system in the occupied mode and lower zone cooling temperature setpoint to be
5F below current ambient temperature to generate a call for cooling. Based on the type of
system and control strategy employed, the following should occur:

In a thermostat application, the Y1 circuit will be energized.

In non-thermostat applications, the microprocessor or central DDC system initiates the

cooling sequence in order to satisfy zone temperature setpoint.

In thermostatically-controlled constant volume systems, the economizer is enabled to

satisfy the first stage call for cooling.

In non-thermostat applications or in VAV units, the economizer modulates to meet the

discharge air temperature setpoint. Hence, the discharge air temperature setpoint should
be adjusted to be only about 1F or 2F below outdoor air temperature to ensure the
economizer will modulate fully without enabling mechanical cooling.

Regardless of system type, adjust the economizer high-limit lockout setpoint to be above
current ambient conditions. If a simple changeover strategy is used, this may include
raising the setpoint. If a differential control strategy is used, it may include overwriting
the return air temperature signal to be above ambient conditions. An alternative, but less
desirable, method is to use a substance like tech spray on the outdoor air sensor to
simulate a cold condition. However, the cold condition may not last long enough to
fully check out the economizer if the outdoor air temperature is extremely high, because
an enthalpy sensor may not respond appropriately.

Check the following:

2.4.1

Supply fan (and return fan if applicable) is operating.

2.4.2

Outdoor air damper modulates to 100% open position.

2.4.3

Return air damper modulates to fully closed position. This is critical because leakage
past return dampers will reduce the effectiveness of the economizer.

2.4.4

DX compressor and condenser are not enabled.

2.4.5

Heating is not enabled.

2.4.6

Power relief fan (if applicable) is enabled when system goes to full economizer
position. Control may be based on building pressure or possibly a limit switch
located on the outdoor air damper.

2.5. Verify mechanical cooling during occupied hours. Compressor operation is typically the
second stage of cooling if the outdoor air conditions are adequate for economizing. Constant
volume units controlled by a zone thermostat will stage mechanical cooling ON when the
thermostat energizes the Y2 circuit, while constant volume systems will stage compressor
operation as necessary to meet a discharge air temperature setpoint. Again, most variable air
volume systems typically control cooling operation based on maintaining a discharge air
temperature setpoint as space temperature deviates from the cooling temperature setpoint.
Leave the system as outlined in step 1.4 above and lower the zone cooling temperature
setpoint to 10F below current ambient temperature. This magnitude of deviation from
setpoint should be adequate to energize the Y2 circuit in a thermostat application and ensure
that the call for cooling remains in non-thermostatically controlled constant and variable air

Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 5 of 9

Functional Testing Guidance

Large Packaged HVAC Systems

volume systems. Also, lower the discharge air temperature setpoint to 10F below outdoor
air temperature to ensure that mechanical cooling will be enabled to meet the new setpoint.
Check the following:
2.5.1

Supply fan (and return fan if applicable) is operating.

2.5.2

Outdoor air damper stays at 100% open position.

2.5.3

Return air damper stays at fully closed position.

2.5.4

DX compressor and condenser are enabled.

2.5.5

Heating is not enabled.

2.5.6

Power relief fan (if applicable) is still enabled.

2.6. Verify economizer high limit lockout control. Leave the system as outlined in step 1.5
above. Adjust the economizer high-limit lockout to be below current ambient conditions.
Check the following:
2.6.1

Supply fan (and return fan if applicable) is operating.

2.6.2

Outdoor air damper returns to minimum ventilation position.

2.6.3

Return air damper opens.

2.6.4

DX compressor and condenser are enabled.

2.6.5

Heating is not enabled.

2.6.6

Power relief fan (if applicable) turns off.

2.7. Verify system operation during unoccupied hours. Simulate an unoccupied condition by
either setting schedule to include actual time the test is being performed or adjusting the time
to be within the unoccupied schedule. Follow the same procedures outlined in steps 1.3 and
1.5, except adjust the unoccupied heating and cooling setpoints to verify night low/high limit
operation. There is no need to recheck economizer operation or cooling staging since these
control sequences have already been verified.
Check the following:

2.8

2.7.1

Supply fan (and return fan if applicable) cycle ON when a call for either heating or
cooling is established, and OFF when the load is satisfied.

2.7.2

Outdoor air damper closed when supply fan is OFF and modulates as necessary when
system is enabled.

2.7.3

Return air damper follows outdoor air damper in reverse.

2.7.4

DX compressor and condenser cycle on and off as necessary.

2.7.5

Heating cycles on and off as necessary.

2.7.6

Relief fan (if applicable) is OFF when the supply fan is OFF and operates as
necessary when the system is enabled.

Return system to normal operation. Return system to normal operating conditions by

enabling correct time and schedules, removing all overrides, and adjusting all setpoints to the
values specified in the design sequence of operations.

3. Smoke Control Test Procedures

Many large package HVAC systems can be operated in different modes to execute various smoke
control strategies. In most cases, implementation of the various smoke control modes requires
Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 6 of 9

Functional Testing Guidance

Large Packaged HVAC Systems

installation of after-factory switches and relays to selectively interrupt and override the standard
factory control sequences. The most common modes include: 1) fire shutdown; 2) pressurization;
3) evacuation; and 4) smoke purge. Each control strategy would typically be initiated manually at
either a fire control panel or through the central DDC system. Each control strategy and general
test procedure description is outlined below.
3.1

Verify system fire shutdown control sequence. Most HVAC systems will be wired and
programmed to shut down automatically upon a signal from the fire control panel. The intent
is to prevent recirculation of smoke-filled or contaminated air back into the space served by
the unit. Proper system operation can be verified when the fire alarm system is tested.
Check the following:

3.2

3.1.1

All fans shut down.

3.1.2

Heating and cooling are disabled.

3.1.3

Outdoor, return, and relief dampers revert to normal positions (i.e. normally open
or closed, etc.).

3.1.4

All smoke and fire dampers associated with the unit close. Note that this is part of
the fire system and not controlled through the microprocessor controller or central
DDC system serving the HVAC unit.

Verify pressurization control sequence. Pressurization mode is intended to keep smoke

out of the zones served by the HVAC unit during a fire event by over-pressurizing these zones
with respect to adjacent zones served by other HVAC units. Execution of this control
strategy requires that the unit have an economizer and the outdoor, return, and relief dampers
operate independently (i.e. separate actuators and control signal). This control sequence will
typically be initiated at the fire control panel or possibly through the central DDC system.
Proper system operation can be verified at any time, but may be most convenient when the
fire alarm system is tested. Leave the system as outlined in step 2.1 above and proceed with
the test.
Check the following:

3.3

3.2.1

All smoke-fire dampers associated with the unit are commanded open before
enabling the HVAC unit.

3.2.2

Outdoor air damper is commanded 100% open.

3.2.3

Supply fan is commanded to operate at 100% flow.

3.2.4

Return and relief dampers are commanded closed.

3.2.5

Return fan or power relief fan (if applicable) remain OFF.

Verify evacuation control sequence. Evacuation mode is intended to remove smoke or

undesirable air from the zones served by the HVAC unit during a fire event without
reintroducing contaminated air into the space. Execution of this control strategy requires that
the unit have an economizer as well as either a return fan or power relief fan, and the outdoor,
return, and relief dampers operate independently (i.e. separate actuators and control signal).
This control sequence will typically be initiated at the fire control panel or possibly through
the central DDC system. Proper system operation can be verified at any time, but may be
most convenient when the fire alarm system is tested. Leave the system as outlined in
step 2.1 above and proceed with the test.
Check the following:
3.3.1

All smoke-fire dampers associated with the unit are commanded open before
enabling the HVAC unit.

Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 7 of 9

Functional Testing Guidance

3.4

Large Packaged HVAC Systems

3.3.2

Outdoor and return air dampers are commanded closed.

3.3.3

Supply fan remains OFF.

3.3.4

Relief dampers are commanded open.

3.3.5

Return fan or power relief fan is commanded ON (fan should operate at full speed
VFD, 2-speed motor, etc.).

Verify smoke purge control sequence. Smoke purge mode is intended to remove smoke or

undesirable air from the zones served by the HVAC unit during a fire event and replace it
with fresh outdoor air. Execution of this control strategy requires that the unit have an
economizer as well as either a return fan or power relief fan, and the outdoor, return, and
relief dampers operate independently (i.e. separate actuators and control signal). This control
sequence will typically be initiated at the fire control panel or possibly through the central
DDC system. Proper system operation can be verified at any time, but may be most
convenient when the fire alarm system is tested. Leave the system as outlined in step 2.1
above and proceed with the test.
Check the following:
3.4.1

All smoke-fire dampers associated with the unit are commanded open before
enabling the HVAC unit.

3.4.2

Outdoor and relief air dampers are commanded open.

3.4.3

Return dampers are commanded closed.

3.4.4

Supply fan is commanded ON (full speed if VFD installed).

3.4.5

Return fan or power relief fan is commanded ON and operate at full speed.

4. Recovery from Power Failure Test Procedures

4.1

Verify system status when power is lost. Most large packaged HVAC systems controlled

by a thermostat, factory-installed microprocessor, or central DDC system will simply shut

down if power is lost to the unit, regardless of system operating status at the time. Most
damper actuators will spring return to normal position and relays will default to normal
positions (open or closed depending on the relay). Simulate a power failure by simply
opening the main power disconnect at the unit. Anticipated system response is based on units
that are not connected to emergency power.
Check the following:

4.2

4.1.1

Supply fan, return fan and/or relief fan, heating elements, and mechanical cooling are
off.

4.1.2

Outdoor and relief air dampers are completely shut.

4.1.3

Return air damper is wide open.

Verify system operation when power is returned. Upon recovery of power, the unit

should be ready for full operation. The internal controls should take the system through an
initialization period before the system is allowed to return to normal operation. When power
is restored, the thermostat, microprocessor, or central DDC system will enable various
circuits depending on programming, setpoints, and space conditions. Many systems have
built-in time delays that may prevent supply fans, compressors, or heating elements from
becoming energized immediately. Simulate a power recovery by simply closing the main
power disconnect at the unit.
Check the following:
4.2.1

Thermostat, microprocessor, or central DDC system does not lose programming.

Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 8 of 9

Functional Testing Guidance

Large Packaged HVAC Systems

4.2.2

Supply fan, return and/or relief fans, heating elements, economizer, and mechanical
cooling start based on command from thermostat after time delays have elapsed (if
applicable).

4.2.3

Outdoor and return dampers modulate to appropriate positions.

4.2.4

Relief fan and damper (if applicable) operate as necessary per sequence of
operations.

5. Trending System Operation

5.1

Verify system operation through trending. It is a good idea to verify proper system

operation under normal operating conditions over time. Oftentimes, operational errors may
not be apparent when a system is forced into a particular operational state via overriding
sensors and changing setpoints. It is recommended that the trending capabilities of a central
DDC system or stand-alone data loggers be used to verify proper system operation under
normal operating conditions. Measurement sample rate can be every 1 to 5 minutes to catch
short cycling and control instability. The trending period can be 1 to 2 weeks, but should
include at least one Monday morning recovery after a weekend.
At a minimum, the following data points should be trended:

Supply, outdoor, return, and mixed air temperatures. This will assist in verifying
economizer operation.

Fan status or amperage. This will assist in verifying proper fan operation during both
occupied and unoccupied modes.

Compressor status or amperage and outdoor air temperature. This will assist in verifying
compressor staging.

Large_Packaged_HVAC_Systems_Test_Guidance.doc (last updated: 8/06)

Page 9 of 9