FAN COIL UNIT | Onsite Functional Testing Procedure with Template

May 22, 2023 |

To ensure that the fan coil units operate in line with the buildings and designers’ requirements, once they have been installed there will be a need to functionally test them.

The functional tests, described below, of the FCU, will check and validate the following:

  • All documentation is in place
  • The installation has been approved and signed off
  • FCU pre-requisites have been completed, to allow testing to commence
  • Documenting of the details of the equipment under test
  • General LMCP tests, if installed
  • Obtaining electrical readings
  • Check safety systems, such as overload and e-stop functions.
  • Proving that the air and water flow rates and temperatures are correct
  • Ensuring the BMS is integrated
  • Checking the calibration of any sensors and instruments
  • Proving the unit functions inline with the sequence of operations/control logic
  • BMS Alarms send the correct signals
  • Verifying that the condensate pan, if installed, and associated pipework drains 
  • The system is set up inline with the designers requirements, once the testing has been concluded

Below we will detail the steps that will be necessary to complete the writing of an FCU functional method statement, once understood we will detail a ‘standard type’ method of testing for a common installation.

If want to read more on fan coil units here is our article Fan Coil Units | What, Where & How
or if want to understand how to write a method statement check out our article HOW TO WRITE A TESTING AND COMMISSIONING METHOD STATEMENT

Table of Contents

🟩 Fan Coil Unit Testing Steps Explained

🟧 Step 1: Documentation and reference material

Review of documentation and reference material needed to complete the works. We have included a list below of the standard documents we would review and investigate.

Don’t forget to make a note of the information, document numbers, titles, etc as will be needed to complete the method statement that is to be issued.

RefDocumentReason
1Commissioning Plan/Specificationto understand the project requirements relating to the testing, including the standards and guides that should be referenced.
2General Project MEP Specificationto understand the project requirements relating to the testing.
3Particular Project MEP Specificationto understand the project requirements relating to the testing.
4Commissioning ProgrammeReviewing the programme will allow for an understanding of when the testing will be completed.
5Material Submission of Fan Coil UnitTo fully understand the equipment, how it operates, the options that may be included, and any specific manufacturer requirements relating to the testing to ensure warranties are met.
6Equipment ScheduleUsually can be found as a drawing, used to understand the specific design requirements of the unit [flow rates, ratings, setpoints, etc].
7Sequence of Operation / Control LogicsUsed to understand the overall control philosophy of the fan coil units, if there are any master/slave type situations, BMS points, fire integrations, and general operational requirements. Β  Be wary, as there can be situations where the logic for one type of space may be different than another. For example, units serving a security room may be different than those serving a corridor.
8Water Side Mechanical Schematic DrawingsTo understand the overall pipework layout, sizes, and flow rates (if shown). Routing of the system including the location of the units under test.
9Water Side Mechanical Layout DrawingsTo understand the types of areas, rooms and how the units are mounted, ceiling, floor, wall, etc.
10Air Side Mechanical Schematic DrawingsTo understand the overall ducting layout and routing of the system including the location of the units under test.
11Air Side Mechanical Layout DrawingsTo understand the types of areas, rooms and how the units are mounted, ceiling, floor, wall, etc.
12Low Voltage Electrical Schematic DrawingsTo understand the design of the power/wiring. Sometimes units or their panels can be dual-fed with an emergency feed, so best to check.
13Low Voltage Electrical Layout DrawingsTo see the locations of the relevant control panels that may be connected to the fan coil units.
14BSRIA Guide BG49-Commissioning Air Systems [or relevant guideline in your country]Used for understanding the tolerances and air balancing requirements & any tools that may be required.
15BSRIA Guide BG2-Commissioning Water Systems [or relevant guideline in your country]Used for understanding the tolerances and water balancing requirements & any tools that may be required.
FCU Functional Testing Method Statement Template [MS Word]

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🟧 Step 2: Review permit to work systems required

This will be very project-specific, but a review should be conducted to understand if there will be at the time of testing any restrictions on the following:

RefPossible RestrictionNotes
1Access to general siteThe people testing the equipment may not be the same people who installed it, at the time of commissioning the site could be under tighter security measures.
2Access to location of equipmentThe equipment could be installed in a restricted space that requires a permit to enter, for example, a computer/server room, security room, BMS room, electrical room, or a room that is occupied, etc. Β  In more extreme circumstances, there could be a requirement for the engineers completing the works to be escorted.
3Access to the equipmentThe equipment could be installed at a high level, above a ceiling, behind paneling, or under a floor. Β  Access should be considered to ensure that the correct equipment and tools are available to stop any aborted works.
4Understanding any restrictions relating to the MEP systems that may be involved in the testingFor example for the fan coil unit testing, if completed during partial handover, the space where the unit is located could be occupied, simulating temperature changes in the space may cause issues. Β  Or, if there is a need to prove the fire trip and the building is occupied this would need to be handled carefully and usually under permit.Β 

🟧 Step 3: Understand how the installations will be inspected, signed off & defects managed

Prior to any testing and commissioning taking place on the equipment and associated systems, the installation should be fully inspected and signed off.

This is usually completed by a resident engineer or the MEP design team.

We would love to have a defect-free system to test, but the reality is that there will generally be something [labeling, cosmetic damage, insulation, etc], and when it comes to the testing, we need to be clear on what is acceptable as an outstanding defect and what is not.

Being proactive is the name of the game when understanding if the defects will actually harm and affect the testing or if they won’t matter. 9/10 they don’t matter.

Either way, it all needs to be very clear. 

🟧 Step 4: Understand system integrations

A fan coil unit will generally have integration with other systems, these should be listed with a high-level expectation to allow the testing to commence and be completed.

Some examples are below:

RefIntegrated withNotes
1Centralized fresh air systemas the FCU will usually rely on fresh air from a central system, to fully commission this will need to be fully operational [balanced and running].
2Centralized extract/recirculation air systemas the space can rely on a recirculation/extract system, to fully commission this will need to be fully operational [balanced and running]
3Centralized chilled water systemThe central air plant and the FCU will need to be supplied with the correct chilled water flow rate and temperatures for full commissioning to be completed
4Centralized hot water systemThe central air plant and the FCU will need to be supplied with the correct chilled water flow rate and temperatures for full commissioning to be completed
5Pumped drainage systemsIf there is a pumped condensate system, usually if the FCU is floor mounted, this should be able to operate to remove the condensate to drain.
6General condensate systems [gravity]Where there is a condensate system installed to remove the condensate created by the cooling coil, this can be via gravity or pumped as above. Β  This should be connected to the drainage system and able to operate. Not causing issues to any other areas of the building.
7Fire alarm systemThere will sometimes be a requirement for the FCU to trip and switch off in the event of a fire. To allow this to be proved the fire alarm system should be operating and able to send the correct signals/log the event.
8BMS/control systemAs the BMS will be integral to reporting the status of the unit, it should be fully commissioned and operating. Β  Able to monitor the required points and alarms etc
9Occupancy/room booking systemIf there is an occupancy/room booking system then this should be operating and able to command the unit to start/stop

🟧 Step 5: Expectations of room finishes

To ensure that the testing environment is as per the expected design requirements and clean, it is very important that the rooms/areas the fan coil unit is located within are understood and explained as per the below requirements:

RefExpectationNotes
1Final doors installedDoors should be in the 'normal operation' position when testing.
2Final windows installedWindows should be in the 'normal operation' position when testing.
3All ceilings installedIncluding all final ceiling tiles/grilles and lights
4All partitions/internal walls installedFully complete with doors etc.
5All flooring completeAny raised floors should be fully installed and complete.

 πŸš€ Don’t forget that the rooms and areas where the centralized plant and equipment is located should also have the same expectation.

The above details the information and data that we will need to understand prior to starting the writing of the functional testing procedure.

FCU Functional Testing Method Statement Template [MS Word]

Fan Coil Unit Method Statement [Including the checklist] Template and Instructions in Microsoft Word allowing any editing for full use.

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🟩 Fan Coil Unit Testing and Commissioning Method Statement

In the following section, we will detail a method statement covering the pre-commissioning, functional commissioning, and sign-off of a standard type of FCU.

The format of the document will cover:

  • Introduction
  • Documentation and reference material used
  • Permit to work systems
  • Delivery/Installation inspections and defect management
  • Equipment information
  • Description of equipment/system and integrations
  • Pre-commissioning checklist [various]
  • Specific design information related to the testing
  • Acceptance criteria and tolerances that are set out within the commissioning specification/guidelines
  • Functional testing sequence
  • Appendices covering documents and information that is required to be attached.

🟧 1.0 Introduction

At the start of all functional testing procedures/method statements, there should be an introduction that covers what the document is about, who it is for, and any specific needs such as approval. These can be a pretty standard template that is slightly tweaked across multiple procedures.

The project requires that all functional testing procedures are submitted to the client’s representatives for review and approval, prior to the works being allowed to take place on-site.

The objective of this procedure is to describe how we will be completing the setup and testing the functions of the fan coil units that have been installed on the project.

All testing is based on the project design information as noted in section 2.

🟧 2.0 Documentation and reference material used

As per Step 2 above, add the information that was reviewed to allow the creation of this document.

The below table details the project information that has been reviewed in order to understand the expectation of this testing:

RefDocument No.DescriptionRevision
1
2
3
4
5

🟧 3.0 Permit to work systems

Inline with Step 3 above, note all permits that will be required to allow the testing to start, including which role will obtain it [contractor, client, CxA, facilities etc], and expected time frame of the process.

The following permit-to-work systems will need to be in place to allow the testing to be conducted:

RefDetail of permit requiredResponsibility to obtain [company]Expected time to obtain
1
2
3
4
5

🟧 4.0 Delivery/Installation inspections and defect management

Prior to any testing being started, the contractor should ensure that in line with the project requirements, the equipment is documented as being inspected when delivered and after installation.

This inspection will be completed by the client’s representative, with a certificate being provided that will accept and confirm that the delivered equipment and installations meet the project requirements.

No testing and commissioning should be conducted until this information has been presented for inspection by the commissioning manager.

Any defects listed from these inspections should be closed with a reinspection being conducted and documented.

If there are any observations or defects noted that have not been closed out, the commissioning manager reserves the right to abort the test if it is felt they will affect and impact the testing outcomes.

The contractor will provide the following documentation:

  • Delivery inspection and acceptance form
  • Installation inspection and acceptance form

🟧 5.0 Equipment information

The below table should be completed at the testing

To allow and ensure that the testing and information collected is correct the following equipment will be used and presented to the commissioning manager for inspection prior to the testing.

All equipment, where applicable, will have a current calibration certificate from an independent international laboratory, which will be logged and detailed in the table below.

Any calibration certificates will be photocopied and included in the appendices at the back of this document for inclusion within the operating and maintenance manuals and final commissioning report.

Equipment TypeCertificate expiry dateModelSerial Number
Volt Meter
Clamp Ammeter
Insulation Tester
Touch Temperature Sensor
Humidity Sensor
Balometer with hood
Vane anemometer
Sound Meter

🟧 6.0 Description of equipment/system and integrations

To ensure that the testing is conducted successfully, correctly, and in line with the designed normal operations of the test area, there will be a requirement for some systems to be operating and integrated.

The below table details these systems and expectations:

RefIntegrated withNotes
1Centralized fresh air systemas the FCU relies on a supply of fresh air from the central ventilation system for the floor/area, it will need to be fully commissioned, balanced, and operational.
2Centralized extract/recirculation air systemas there is a dedicated extract/recirculation system installed extracting air back to the AHU system via the ceiling void, this could affect the operation and readings from the FCU if not fully operating. The system will need to be fully commissioned, balanced, and operational.
3Centralized chilled water systemas the FCU & AHU incorporates chilled water cooling coils, the centralized chilled water system will need to be fully operational. It will need to be fully commissioned, balanced.
4Centralized hot water systemas the FCU & AHU incorporates heating water coils, the centralized hot water system will need to be fully operational. It will need to be fully commissioned, balanced.
5Pumped drainage systemsas condensate from some fan coils is pumped, the system should be fully operational.
6General condensate systems [gravity]All drainage systems should be fully tested and connected to allow the condensate to be removed from the building.
7Fire alarm systemThe fire alarm system should be fully active and commissioned as some FCU's will be tripped, switched off, during a fire alarm.
8BMS/control systemAs the BMS will be integral to reporting the status of the unit, it should be fully commissioned and operating, able to monitor the required points and alarms, etc.

🟧 7.0 Pre-commissioning checklists and pre-requisites

The below will be completed, reviewed, and inspected prior to the testing taking place. This is to ensure that all requirements are in place and met so that there are no issues later in the testing that is not expected:

🟨 7.1 Project/info and equipment verification:

Date
Start date of testing/checks[add]
Finish date of testing/checks[add]
RefDescriptionInformation
1Project name[add]
2Equipment number[add]
3LMCP number[add]
4DB powered from
4Room/area[add]
5System typeChilled Water

🟨 7.2 General documentation checks

RefGeneral documentation checksYesNon/a
7.2.1All permits to works in place and available
7.2.2Testing method statement approved.
7.2.3Technical/material submissions approved with all comments addressed and signed off.
7.2.4Equipment data sheets and fan curves available.
7.2.5Drawings available, approved, clear, at a readable scale, and marked up with the testing area.
7.2.6Control logics/sequence of operations approved and attached.
7.2.7Delivery inspection form available for inspection, with any observations, addressed and accepted by the inspection team.
7.2.8Installation inspection form available for inspection, with any observations, addressed and accepted by the inspection team.

🟨 7.3 General installation checks

RefGeneral Installation checksYesNon/a
7.3.1Permanent labels installed
7.3.2Casing condition good: no dents
7.3.3Equipment is clean
7.3.4Maintenance access doors close tightly - no leaks
7.3.5Plenums [intake and supply] fitted correctly and no leaks
7.3.6Vibration isolation equipment installed & shipping bolts removed
7.3.7Maintenance access acceptable for unit and components
7.3.8Sound attenuation installed
7.3.9Thermal insulation properly installed and according to specification
7.3.10Instrumentation installed according to specification (thermometers, pressure gauges, flow meters, etc.)
7.3.11Filters installed and replacement type and efficiency permanently affixed to housing--construction filters removed
7.3.12As per section 6.0, all systems are running as per design requirements
7.3.13Final doors installed and in the position of 'normal operation'
7.3.14Final windows installed and in the position of 'normal operation'
7.3.15All ceilings installed
7.3.16All partitions/internal walls installed
7.3.17All flooring complete

🟨 7.4 Pipework, coil and valve checks

RefPipework, coils, and valvesYesNon/a
7.4.1Pipe fittings complete and pipes properly supported
7.4.2All valves, instruments, and equipment installed as per the drawing
7.4.3Pipes properly insulated with no damage to insulation risking condensation
7.4.4Pipes properly labeled
7.4.5Valves labeled as per the drawings
7.4.6Strainers in place and clean with the correct mesh size
7.4.7Piping system pressure tested
7.4.8Piping system properly flushed and cleaned
7.4.9Piping system properly balanced [under separate method statement]
7.4.10All coils are clean and fins are in good condition
7.4.11The condensate drain pan is clean and angled/sloped to drain
7.4.12Condensate trap installed
7.4.13Sensors have been calibrated

🟨 7.5 Fan, ducts and damper checks

RefFans, ducts, and damper checksYesNon/a
7.5.1Fan and motor alignment ok.
7.5.2Fan checked to rotate the correct way
7.5.3Equipment is clean internally including fan blades.
7.5.4Fan motor lubricated.
7.5.5Ductwork pressure testing where required.
7.5.6Ductwork cleaned to specification where required.
7.5.7Ducting balanced [supply/intake air under separate method statement]
7.5.8Fresh air ducting installed as per drawings and correct size with appropriate turning vanes.
7.5.9Recirculating air installed as per drawings and correct size with appropriate turning vanes.
7.5.10Sound attenuators installed as per drawings and correct size with appropriate turning vanes.
7.5.11Supply ducting installed as per drawing and correct size.
7.5.12Ducting is in good condition and not damaged.
7.5.13All insulation is installed with no damage or risk of condensation forming.
7.5.14Flexible ducting installed as per drawings with a maximum length of 1.5m.
7.5.15Volume control dampers installed as per drawings.
7.5.16Smoke and fire dampers installed as per drawings with appropriate access.

🟨 7.6 Electrical and control checks

RefElectrical and control checksYesNon/a
7.6.1Power disconnects and emergency stops installed and labeled
7.6.2All electric connections tight
7.6.3Proper grounding installed for components and unit
7.6.4Control system interlocks ready and operating
7.6.5Smoke detectors in place and VAC trip signal ready
7.6.6All control devices, pneumatic tubing, duct/wall-mounted sensors, and wiring complete
7.6.7Point to points tests have been completed
If creating a document, the below tables can be combined, apart from 8.1. We have just split as space is limited

The below tables detail the specific design requirements related to the equipment being tested:

🟨 8.1 Room temperature, humidity set points and time clock

Area/Room/ZoneTemperature Set Point [+/-2Β°C]Humidity Set Point [+/-10%]Operating times of equipment
[add areas/room/zone][add][add]Β [add]
[add areas/room/zone][add][add]Β [add]
[add areas/room/zone][add][add]Β [add]
[add areas/room/zone][add][add]Β [add]

🟨 8.2 Equipment ventilation flow rates

Equipment Reference NumberSupply air design flow rateFresh air design flow rateΒ Recirculation air design flow rate
[add][add][add][add]
[add][add][add][add]
[add][add][add][add]
[add][add][add][add]
[add][add][add][add]
[add][add][add][add]

🟨 8.3 Equipment information [chilled water temperatures]

Equipment Reference NumberChw supply design tempChw return design tempChw design flow rateChw coil rating [KW]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]

🟨 8.4 Equipment information [heating water temperatures]

Amend if electric coil used
Equipment Reference NumberLthw supply design tempLthw return design tempLthw design flow rateLthw coil rating [KW]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]
[add][add][add][add][add]

 πŸŸ¨ 8.5 Equipment information [chilled water flow rates]

Equipment Reference NumberChw Design Flow RateLphw Design Flow RateSupply Air Design Flow RateFresh Air Design Flow RateΒ Recirculation Air Design Flow Rate
[add][add][add][add][add][add]
[add][add][add][add][add][add]
[add][add][add][add][add][add]
[add][add][add][add][add][add]
[add][add][add][add][add][add]
[add][add][add][add][add][add]

🟨 8.6 BMS points, alarms and control logic

All BMS points and alarms will be proved as per the approved BMS points/alarm list detailed within the appendix.

We have included the control logic and sequence of operations for the equipment being tested within the appendices.

🟧 9.0 Acceptance criteria and tolerances that are set out within the commissioning  specification/guidelines

The following details the testing tolerances that will be utilized during the testing, these have been obtained from the project information, codes, guides, and standards:

System TypeTolerance
Water Side [<0.1l/s]-0.5
Air Side+/-20% of the lowest terminal unit

🟧 10.0 Functional testing sequence

Note: the below is provided as an example, its a very common method of testing but be aware that projects can be different

The following testing will be completed on each piece of equipment:

RefDescriptionInformation to collect
10.1Β Push the lamp test button on the LMCPAll lamps should light up.
10.2Push the buzzer test alarm button on the LMCPThe buzzer should sound.
10.Β 3Start the fan coil unit and firstly verify the emergency stop function.Ensure unit stops, and alarm sent to BMS.
10.4Β Put the FCU into manual and confirm that the manual switching for the start/stop function worksFCU manually can be started and stopped at the LMCP/control panel. BMS signal sent of FCU status.
Β 10.5With the fan running, measure the running currents at each speed [low, medium & high]
Β 10.6Verify the overload protection operates to protect the unitThe unit shuts down, sending a signal to BMS
10.7Β With the FCU in automatic, prove the time clock function of the FCU by modifying the ON/OFF programmed time. Set to come on and run for 2 minutes before shutting off again.The FCU automatically starts and stops in line with the times inputted, sending a signal to BMSΒ Β 
10.8Verify all points and alarms, send the correct signals as per the approved BMS points list. These could cover: [Room temperature, High-temperature alarms, Temperature setpoints, On/Off status, Speed control status, low, medium, high, modulating valve control]Signals sent
Β 10.9With the fan speed set to medium and modulating valve fully open, measure and document the chilled/heating water flow rates.Should be in line with the design requirements as noted in section 8.0 and tolerances section 9.0.
Β 10.10With the fan speed set to medium measure the supply airflow and recirculating/return air.Should be in line with the design requirements as noted in section 8.0 and tolerances section 9.0.
Β 10.11Verify that the drain/condensate pan operates and allows the condensate to flow away under gravity [if not pumped], by pouring 2 liters of water into the pan.All water should drain away.
Β 10.12Once all testing has been completed, check that the temperature set points as noted in section 8.1 are inline.
Β 10.13Ensure that any time clock functions are as per the requirements in section 8.0.
Β 10.14Generally, it is very difficult to accurately measure and calculate the coil performance once the equipment is installed. With this in mind, the performance of the unit will be acceptable if all above has been verified and the details of the unit meet the material/technical submission.

🟧 12.0 Appendices covering documents and information that is required to be attached.

🟧 Appendix A – Material Submission

Prior to the testing, insert a copy of the approved material submission for the record.

🟧 Appendix B – BMS Points List

Prior to the testing, insert a copy of the approved BMS Points List for the record.

🟧 Appendix C – Water Side Mechanical Schematic

Prior to the testing, insert a copy of this approved drawing, marked up showing the area tested for the record.

All drawings must be at a scale and printed on a page size that is clearly readable. An A4 scan of the whole building showing a FCU as a splodge will not be accepted]

🟧 Appendix D – Water Side Mechanical Layout

Prior to the testing, insert a copy of this approved drawing, marked up showing the area tested for the record.

All drawings must be at a scale and printed on a page size that is clearly readable. An A4 scan of the whole building showing a FCU as a splodge will not be accepted]

🟧 Appendix E – Air Side Mechanical Schematic

Prior to the testing, insert a copy of this approved drawing, marked up showing the area tested for the record.

All drawings must be at a scale and printed on a page size that is clearly readable. An A4 scan of the whole building showing a FCU as a splodge will not be accepted]

🟧 Appendix F – Air Side Mechanical Layout

Prior to the testing, insert a copy of this approved drawing, marked up showing the area tested for the record.

All drawings must be at a scale and printed on a page size that is clearly readable. An A4 scan of the whole building showing a FCU as a splodge will not be accepted]

🟧 Appendix G – Electrical Schematic Layout

Prior to the testing, insert a copy of this approved drawing, marked up showing the area tested for the record.

All drawings must be at a scale and printed on a page size that is clearly readable. An A4 scan of the whole building showing a FCU as a splodge will not be accepted]

🟧 Appendix H – Electrical Layout

Prior to the testing, insert a copy of this approved drawing, marked up showing the area tested for the record.

All drawings must be at a scale and printed on a page size that is clearly readable. An A4 scan of the whole building showing a FCU as a splodge will not be accepted]

🟧 Appendix I – Fan Curves

Prior to the testing, insert a copy of this approved document for the record, if used, for each type of equipment tested.

🟧 Appendix J – Equipment Data Sheets

Prior to the testing, insert a copy of this approved document for the record, if used, for each type of equipment tested.

🟧 Appendix K – Calibration Certificates

Prior to the testing, insert a copy of these certificates for the record.


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⬜ Fan Coil Unit Method Statement [PDF]


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