Fault Detection and Diagnostics for Rooftop Air Conditioners

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NOMENCLATURE A Sensor surface area ANN Artificial neural network BP Back-propagation ∆ T ca Condenser air temperature difference ∆ T ea Evaporator air temperature difference FDD Fault detection and diagnosis GRNN General regression neural network h o Heat transfer coefficient between sensor and ambient air I t Irradiation on sensor exterior surface ma Mixed air oa Outdoor air ra Return air RBF Radial basis function RMS Root mean square RTU Rooftop unit T amb Ambient temperature t a Air temperature T cond Condensing temperature T dis Discharge line temperature T Evaporating temperature evap T ll Liquid line temperature T ma Mixed air temperature T oa Outdoor air temperature T ra Return air temperature t s Sensor surface temperature (sensor’s reading) T sc Subcooling T sh Superheat W ma Mixed air humidity ratio W oa Outdoor air humidity ratio W ra Return air humidity ratio τ Transmittance ρ Reflectance α Absorptance 3
1. Introduction All the thermodynamic states of a rooftop air conditioning unit (RTU) are functions of external driving conditions and various faults, as is shown in figure 1.1. It is important for fault detection and diagnosis (FDD) not to misinterpret variations in thermodynamic states caused by changes in the driving conditions for faults. If measurements are classified directly, the classification rules have to be complicated to consider the effect of external driving conditions. Faults External Driving conditions: T , T , W oa ma ma RTU , All thermodynamic states, T T , T , T , T , T ll cond evap dis sc sa Figure 1.1 Rooftop system In order to simplify classification and improve overall FDD performance, model-based FDD techniques usually use some type of model to predict expected values (normal behavior) of measured performance indices using measured external driving conditions for the equipment which is being monitored. Often, the difference between expected and actual measurement values (residuals) will always be zero mean when there are no faults. The probability distribution of residuals is a weak function of driving conditions and is strongly dependent on faults. So if residuals are used to detect and diagnose faults, the classifier may not need to consider driving conditions and is simplified considerably. There are three general types of models: physical, black box and gray box. Physical models, whose parameters and structures have some physical significance, are derived from fundamental physical laws. An accurate physical model is capable of extrapolating performance expectations well in case of limited training data. However, it is difficult and expensive to develop an accurate physical model. Also, a complex physical model involves large collections of nonlinear equations which are difficult to solve. In addition, physical models are not accurate enough for a given system and require detailed data for training. 4
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CALIFORNIA ENERGY COMMISSION Final
Page 3 and 4: Acknowledgements Jim Braun and Haor
Page 5 and 6: Abstract Project 2.1, Fault Detecti
Page 7 and 8: TABLE OF CONTENTS LIST OF TABLES LI
Page 9 and 10: LIST OF FIGURES Page 1 - Field Test
Page 11 and 12: The report “Description of Labora
Page 13 and 14: mounted heat pumps for heating and
Page 15 and 16: The retail stores are in Southern C
Page 17 and 18: Figure 1 - Field Test Sites Data Co
Page 19 and 20: Gibson School (Cont’d) Woodland S
Page 21 and 22: Table 1 - Data List for Modular Sch
Page 23 and 24: BUILDING TYPE: Modular School Rooms
Page 25 and 26: HEATING / AIR CONDITIONING EQUIPMEN
Page 27 and 28: Sacramento Area McDonalds PlayPlace
Page 29 and 30: Bradshaw Road (Sacramento Area) McD
Page 31 and 32: TEST INSTRUMENTATION: Tables 2 and
Page 33 and 34: Table 2 - Data List for Inland Rest
Page 39 and 40: Castro Valley (San Francisco Bay Ar
Page 41 and 42: Castro Valley McDonalds PlayPlace P
Page 43 and 44: more or less custom design, publish
Page 45 and 46: BUILDING TYPE: Retail Store ADDRESS
Page 47 and 48: TEST INSTRUMENTATION: Similar test
Page 49 and 50: • Temperature and humidity levels
Page 51 and 52: November 2001 - December/January 20
Page 53: Table of Contents 1. Introduction..
Page 57 and 58: Table 1.1 Comparisons of Three Mode
Page 59 and 60: solution procedure involves the non
Page 61 and 62: independent of the moisture content
Page 63 and 64: function, f ( X , y) , if it can be
Page 65 and 66: Figure 2.1 Neural-Network Implement
Page 67 and 68: prototype was developed by using th
Page 69 and 70: 3. Comparison of black-box modeling
Page 71 and 72: which is more accurate than the exp
Page 73 and 74: Similar to GRNN, RBF has very good
Page 75 and 76: Table 3.2 RMS error (Polynomial,GRN
Page 77 and 78: Table 3.4 Contrast of Black-box mod
Page 79 and 80: Polynomial plus GRNN Training Desir
Page 81 and 82: interpolation(poly+GRNN) extrapolat
Page 83 and 84: used to build the steady-state mode
Page 85 and 86: α , ρ, τ I t t s h o A t a Figur
Page 87 and 88: Temperature (F) 82 79 76 73 Condens
Page 89 and 90: 0.050 0.045 Pressure = 101.3 [kPa]
Page 91 and 92: T T − T − T W = W −W −W m =
Page 93 and 94: Figure 4.8 Output of three steady-s
Page 95 and 96: will be calculated to represent the
Page 97 and 98: 180 175 RMS error = 0.3984 (F) Pred
Page 99 and 100: 180 175 RMS error =1.1472 (F) Predi
Page 101 and 102: 51 50 RMS error=0.3860 (F) Predicte
Page 103 and 104: 4.4 California field site results S
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105 100 RMS error =0.5982 (F) Predi
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Since air conditioners always cycle
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6. Conclusions and future work So f
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Lee, W., House, J.M. and Shin, D.R.
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Table of Contents 1 Introduction...
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AHU α β 2 d i EER ∆ ∆ η v T
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Paper statistics in HVAC FDD Number
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6 24 122 7) 6 3++, ) . !! /011
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336 F / s $ S
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N $ V v1
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Figure 3-4 2-dimensional residual d
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10 5 Normal and current operation p
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7 N Ω f N N Ω = Ω X ,
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0 + α 6 d χ ( )
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Normal operation region Residual-2
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Table 3-2 Refrigerant Leak at 20% l
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ratio dist = P F 1 P F 1 2 1 9.0
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$ , " - (
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)(( 0( 04 ) 6330" /
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Table 4-2 Polynomial plus GRNN mode
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4.2 m r,predict (kg/min) 4 3.8 3.6
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6 1)( ( ( 6 1)( ) , ( )
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- )
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? "J> *"J060 #"J083 *$"J670 #"J08<
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Table 4-17 Detected (normal, fault)
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c=1 c=10 c=20 1 0.8 Distance ratio
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$ /) $ 0111" .. !!
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Chen, Bin and Braun, J.E, 2000. Sim
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Ventilating, Air-Conditioning and R
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1.T amb 2.T ra 3.RH ra Plant Prepro
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F) $
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+: + $ 5
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.44(' * 5 09( ( 0( F N ( M , Σ)
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Load 20% 40% 60% 80% 100% 3 4 Fault
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Load 20% 40% 60% 80% 100% 3 4 Fault
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3 4 0 0 0 0 0.4173 0 0.0010 0 0.000
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.44(' $ () ) ) - $
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∆P Restrictio n Level=100%* ∆P
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2 TABLE OF CONTENTS TABLE OF CONTEN
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4 A1.2.3 Valve Position Expression
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6 Figure 2-10 Decoupling refrigeran
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8 LIST OF TABLES Table 1-1 Fault di
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10 N = Number of generated sample p
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12 with a fixed-orifice as the expa
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14 (residuals) should have a zero m
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16 expected distribution of the res
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18 operation. Another advantage is
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20 1.1.2.1 Original SRB Fault Diagn
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22 Corresponding to the SRB fault d
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24 integration of the probability d
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26 1. Simplifies fault detection fr
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28 Step i Do FDD on fault i . After
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30 ROOFTOP UNIT FAULTS COMPONENT-LE
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32 has two possible causes: refrige
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34 1.2.3 Decoupling of Component Fa
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36 1.2.3.2 Condenser-Related Faults
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38 mixture, χ ref is known as the
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40 Table 1-3 also lists the refrige
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42 Refrigerant Property T cond, pre
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44 as an independent feature only f
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46 evaporator air flow rate reducti
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48 5. 2 Pll ∆ deviates drasticall
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50 System-Level Faults RefUnder Ref
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52 1.2.5 Summary of Decoupling Sche
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54 noise, system disturbances and m
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56 compressor data. When there is a
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58 Figure 2-5 Decoupling evaporator
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60 Total Pressure Drop of Liquid- L
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62 Figure 2-11 Illustration of Demo
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64 bypass the compressor. At this t
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66 for T dis because there is no ov
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68 Figure 2-14 Outputs of the FDD d
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70 the system requires more refrige
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72 recommended that: the system req
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74 Figure 2-20 Outputs of the FDD d
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76 Figure 2-21 Histogram bar plot o
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82 2.3.2 Summarized Results for Oth
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84 3 CONCLUSIONS AND RECOMMENDATION
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86 Breuker, M.S. and Braun, J. E.,
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88 Lee, W., House, J.M. and Shin, D
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90 APPENDIX 1 PHYSICAL MODELS OF EX
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92 A1.1.2 Short-Tube Models Many re
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94 m& = CA ρ P up − P ) (A1-5) (
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96 The abrupt change of CA for the
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98 These equations can be combined
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100 H h T sh , max opening T sh , s
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102 A1.2.5 Parameter Estimation Met
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104 T (2 T sh, ratingopening , sh,m
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106 Harms’Result Harms plotted al
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108 Mass flow rate Local linearizat
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110 temperature on the RTD is unifo
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112 in cold water application, it i
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1 ACKNOWLEDGEMENTS The research tha
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3 2.2.3 Todd Harms’ Data ........
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5 LIST OF FIGURES Figure E-1. FDD d
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7 LIST OF TABLES Table E-1 FDD resu
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9 IA = Independence Assumption λ i
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11 EXECUTIVE SUMMARY Packaged air c
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13 current values of the fault indi
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15 Figure E-4 Histogram of the EER
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17 2. Operational cost savings, whi
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19 Table E-5 Conservative Lifetime
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21 constraints. Economic constraint
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23 Paper statistics in HVAC FDD 35
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25 on directional changes to identi
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27 fault levels at different operat
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29 was concluded that the method wa
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31 However, several improvements ar
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33 point sensor placement is genera
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35 2 DATA SOURCES USED FOR EVALUATI
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37 The fives types of faults are re
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39 Occupation Type Climate Location
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41 The SRB FDD method determines wh
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43 The following sections describe
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45 points rather than on a distribu
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47 current operation point P 1, P F
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49 4 A DECOUPLING-BASED FDD TECHNIQ
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51 This approach overcomes the draw
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53 ⎡ ∆T ⎢ ⎢ ∆T 2 ⎢ ∆
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55 improving the compressor model p
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57 Condenser Air Mass Flow Rate (lb
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59 Evaporator Air Mass Flow Rate (l
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61 Liquid-Line Pressure Drop (PSI)
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63 4.2.2 Purdue Field Emulation Sit
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65 1. Evacuated the system, and the
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67 normal _ value − current _ val
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69 Figure 4-16 shows one frame afte
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71 Figure 4-18 shows one frame afte
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73 valve position can be seen from
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Figure 4-22 Outputs of the FDD demo
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83 4.2.3.2 Summarized Results for O
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85 5 ECONOMIC ASSESSMENTS Since the
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87 inspection savings would be $2,0
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89 Q & Cap = W & × EER (5-2) The e
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91 4. electricity costs ( C e ). Ut
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93 Table 5-3 lists estimates of equ
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95 5.4 Smart Service Schedule Savin
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97 7. A 6-ton RTU having a cost of
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99 Location North California South
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101 5. Three case studies were inve
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103 REFERENCES Aaron, D. A., and P.
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105 Davis, Coby. 1993. Comparison o
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107 Rossi, T.M., 1995. Detection, D
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Fault Detection and Diagnostics for Rooftop Air Conditioners

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