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Rooftop Fundamentals
• Packaged air handler with heating and cooling source built in– Typically gas fired heating with compressor cooling– Economizer required by all regional codes for
equipment above 5 cooling tons (less in some cases)– Building ventilation handled by the package unit with
outdoor air introduced into the mixed air plenum• Almost 80% of all HVAC systems use this sort of
package technology• Particularly important in small commercial and
“big box” applications in suburban and exurban applications
Operational Issues
• Most economizers are assumed to provide up to half of the cooling requirement
• Surveys of economizer operation concluded that at least 50% are broken or not optimized
• Simple controllers, inaccurate sensors, and primitive dampers insure minimal functionality in many units.
• O&M contracts seldom extend to unit operation or efficiency
PSE Premium Rooftop Service
• Operated since 2003 with about 10 contractors
• Serviced about 2000 rooftop units
• Provided training for about 150 service technicians
• Focused on economizer and air flow
• Limited to units under 25 tons
Analysis Packages
• Package 1: Basic Service– Check thermostat type/settings– Measure economizer airflows; adjust as needed– Adjust economizer changeover temperature– Clean coils
• Package 2: Basic Service/Repair– Basic Service plus– Wire/enable morning warm-up control (heating savings)– Repair outside air or return air damper
• Package 3: Thermostat– Basic Service plus– Install two-stage cooling thermostat– Wire/enable morning warm-up control
Analysis Package (Cont.)
• Package 4: CO2 Control– Basic Service plus– Add CO2 sensor and needed economizer controller
• Package 5: Conventional controller– Basic Service plus– Replace economizer controller
• Package 6: Controller plus thermostat– Basic Service plus– Install 2 stage cooling thermostat and new econo. controller
• Package 7: New Economizer– Install new economizer on existing unit and – Perform Basic Service
Cost of Measures
Cost Assumptions:
Basic Service 350
Thermostat 200
Controller 250
CO2/Controller 600
Warm-up Relay 100
Economizer 1500
• Assumes a 5-10 ton rooftop unit
• Annual maintenance normalized to a 5 year basic maintenance cycle
• Applied to 7.5 ton, 3000 sf zone
Assumptions
• Cooling equipment modeled at 8.3 EER• Heating equipment efficiency .80• 3000 square feet, 7.5 ton RTU (single zone operation
and control)• 20% Make-up air setting (Package 1,3,5,7)• 30% Make-up air setting (Package 4,6)• 50% Make-up air (Stuck damper, Package 2)• 35% mixed air leakage (65% maximum outside air)• LPD: 1.55 w/sf, office. 3.05 w/sf, retail• Broken damper: stuck at 50% make-up• No warm-up control• 55 F economizer change-over
Seattle Office
Pac
kage
Base Treatment Savings Cost Life O&M
Heating Cooling Heating Cooling Heating Cooling
kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf $/sf yrs $/sf
Basic 5.01 1.43 5.01 0.95 0.00 0.48 0.12 15.00 0.02
Repair 9.56 1.14 4.65 0.95 4.92 0.19 0.15 15.00 0.02
T-Stat 5.01 1.43 4.65 0.95 0.37 0.48 0.22 15.00 0.02
DCV 6.46 1.37 2.13 0.95 4.34 0.42 0.32 15.00 0.02
Control 5.01 1.43 4.65 0.95 0.37 0.48 0.20 15.00 0.02
Reset 6.46 1.38 4.65 0.95 1.82 0.43 0.27 15.00 0.02
New Econ 5.01 1.61 4.65 0.98 0.37 0.63 0.62 15.00 0.02
Rooftop O&M Boise Office
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
Se
rvic
e
Re
pa
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T-s
tat
DC
V
Co
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Ne
w E
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Measures
kW
h/s
f
Heat
Heat Save
Cool
Cool Save
Boise, Office
Pac
kage
Base Treatment Savings Cost Life O&M
Heating Cooling Heating Cooling Heating Cooling
kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf $/sf yrs $/sf
Basic 6.79 2.32 6.79 1.90 0.00 0.42 0.12 15.00 0.02
Repair 12.99 2.31 6.43 1.90 6.57 0.42 0.15 15.00 0.02
T-Stat 6.79 2.32 6.43 1.90 0.37 0.42 0.22 15.00 0.02
DCV 8.82 2.34 2.92 1.80 5.90 0.54 0.32 15.00 0.02
Control 6.79 2.32 6.43 1.90 0.37 0.42 0.20 15.00 0.02
Reset 8.82 2.38 6.43 1.90 2.40 0.48 0.27 15.00 0.02
New Econ 6.79 2.38 6.43 1.85 0.37 0.53 0.62 15.00 0.02
Rooftop O&M Seattle Retail
0.00
2.00
4.00
6.00
8.00
Se
rvic
e
Re
pa
ir
T-s
tat
DC
V
Co
ntr
olle
r
Re
se
t
Ne
w E
co
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Measures
kW
h/s
f
Heat
Heat Save
Cool
Cool Save
Seattle Retail
Pac
kage
Base Treatment Savings Cost Life O&M
Heating Cooling Heating Cooling Heating Cooling
kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf $/sf yrs $/sf
Basic 1.83 3.69 1.83 2.50 0.00 1.19 0.12 15.00 0.02
Repair 6.32 3.08 1.76 2.50 4.56 0.58 0.15 15.00 0.02
T-Stat 1.83 3.69 1.76 2.50 0.07 1.19 0.22 15.00 0.02
DCV 3.56 3.73 0.72 2.41 2.84 1.32 0.32 15.00 0.02
Control 1.83 3.92 1.76 2.50 0.07 1.42 0.20 15.00 0.02
Reset 3.56 3.73 1.76 2.50 1.80 1.23 0.27 15.00 0.02
New Econ 1.83 4.30 1.76 2.53 0.07 1.77 0.62 15.00 0.02
Rooftop O&M Boise Retail
0.00
2.00
4.00
6.00
8.00
Se
rvic
e
Re
pa
ir
T-s
tat
DC
V
Co
ntr
olle
r
Re
se
t
Ne
w E
co
n
Measures
kW
h/s
f
Heat
Heat Save
Cool
Cool Save
Boise Retail
Pac
kage
Base Treatment Savings Cost Life O&M
Heating Cooling Heating Cooling Heating Cooling
kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf kWh/sf $/sf yrs $/sf
Basic 2.38 4.64 2.38 3.79 0.00 0.85 0.12 15.00 0.02
Repair 7.17 4.50 2.31 3.79 4.86 0.71 0.15 15.00 0.02
T-Stat 2.38 4.64 2.31 3.79 0.07 0.85 0.22 15.00 0.02
DCV 4.26 4.99 1.24 3.66 3.02 1.33 0.32 15.00 0.02
Control 2.38 5.09 2.31 3.79 0.07 1.30 0.20 15.00 0.02
Reset 4.26 4.99 2.31 3.79 1.95 1.20 0.27 15.00 0.02
New Econ 2.38 5.29 2.31 3.78 0.07 1.51 0.62 15.00 0.02
Results
• Overall savings in Seattle are about 1300 kWh for cooling and about 40 Therms heating without repairs
• Repairs or CO2 control increases heating savings by a factor of ten.
• Costs for Basic Service packages vary from $350 to $800 (higher cost includes thermostat and controller)
• Costs for CO2 sensor plus needed controller with Basic Service is about $950