Methods and systems for automated HVAC testing

1. A method of testing an HVAC unit using an energy management system, the HVAC unit having a plurality of components, the HVAC unit being configured to operate in at least a first stage, the energy management system including a controller for setting the HVAC unit mode and for changing set points in a thermostat controlling the HVAC unit, the controller further receiving snapshots of supply temperatures from a temperature sensor, the method comprising:

setting, with the controller, the HVAC unit to a fan only mode for a first predetermined amount of time;

taking, with the temperature sensor, a first snapshot before the end of the first predetermined amount of time;

changing, with the controller, a set point in the thermostat to a temperature sufficient to cause the HVAC unit to operate in the first stage in which at least a first component among the plurality of components is operating;

taking, with the temperature sensor, during operation of the first stage, a second snapshot before the end of a second predetermined time after a start of operation of the first stage; and

determining, with the controller, a rate of change of the supply temperature during operation of the first stage based on a temperature differential between the first and second snapshots and a time differential between the first and second snapshots.

2. The method of claim 1 , wherein the set point is sufficient to cause the HVAC unit to operate in a second stage in which at least a second component among the plurality of components is operating,

the method further comprising:

taking, with the temperature sensor, during operation of the second stage, a third snapshot before the end of a third predetermined time after a start of operation of the second stage;

determining, with the controller, a rate of change of the supply temperature during the operation of second stage based on a temperature differential between the second and third snapshots and a time differential between the second and third snapshots; and

determining, with the controller, a rate of change of the supply temperature during operation of the first and second stages based on a temperature differential between the first and third snapshots and a time differential between the first and third snapshots.

3. The method of claim 2 , wherein the HVAC unit the HVAC unit is further configured to operate in a third stage that is a heating stage, further comprising:

changing, with the controller, the set point in the thermostat to a temperature sufficient to cause the HVAC unit to operate in the third stage in which at least a third component among the plurality of components is operating after the second stage;

taking, with the temperature sensor, during operation of the third stage, a fourth snapshot before the end of a fourth predetermined time after a start of operation of the third stage; and

determining, with the controller, a rate of change of the supply temperature during operation of the third stage based on a temperature differential between the third and fourth snapshots and a time differential between the third and fourth snapshots.

4. The method of claim 3 , further comprising:

determining, with the controller, a rate of change of the supply temperature during operation of the first, second, and third stages based on a temperature differential between the first and fourth snapshots and a time differential between the first and fourth snapshots.

5. The method of claim 1 , further comprising:

transmitting, with the controller, the rates of change to a sever remote from a facility where the HVAC unit is located; and

comparing, with the server, the rates of change to one or more of:

a previous rate of change for the HVAC unit,

a rate of change for another HVAC unit at the same facility, and

a rate of change for another HVAC unit at a different facility.

6. The method of claim 1 , wherein the HVAC unit comprises multiple HVAC units, the method further comprising:

grouping, with the energy management system, the first and second stages for each HVAC unit of the multiple HVAC units to define a sequence of heating and cooling tests for the multiple HVAC units; and

executing, with the energy management system, the sequences of heating and cooling tests at a predetermined time.

7. The method of claim 6 , wherein the sequence of heating and cooling tests allows each HVAC unit to be tested at a different time of day.

8. The method of claim 6 , further comprising defining, with the energy management system, a schedule that allows each HVAC unit to be tested before a seasonal change.

9. The method of claim 1 , further comprising:

predicting a failure or a malfunction of the first component based on the determined rate of change of the supply temperature during operation of the first stage.

10. The method of claim 1 , wherein the HVAC unit comprises multiple HVAC units at multiple facilities, the method further comprising:

combining, with the energy management system, the rates of change for each stage of the multiple HVAC units;

calculating, with the energy management system, a trend for each combined stage of the multiple HVAC units; and

issuing, with the energy management system, a notification when the trend indicates that a malfunction is expected to occur.

11. A method of testing an HVAC unit using an energy management system, the HVAC unit having a plurality of components, the HVAC unit being configured to operate in at least a first stage, the energy management system including a controller for setting the HVAC unit mode and for changing set points in a thermostat controlling the HVAC unit, the controller further receiving snapshots that include a supply temperature from a temperature sensor and a power measurement from a power sensor, the method comprising:

setting, with the controller, the HVAC unit to a fan only mode for a first predetermined amount of time;

taking, with the temperature and power sensors, a first snapshot before the end of the first predetermined amount of time;

changing, with the controller, a set point in the thermostat to a temperature sufficient to cause the HVAC unit to operate in the first stage in which at least a first component among the plurality of components is operating;

taking, with the temperature and power sensors, during operation of the first stage, a second snapshot before the end of a second predetermined time after a start of operation of the first stage; and

determining, with the controller, a rate of change per kW of the supply temperature during operation of the first stage based on a temperature differential between the first and second snapshots and a power differential between the first and second snapshots.

12. The method of claim 11 , wherein the set point is sufficient to cause the HVAC unit to operate in a second stage in which at least a second component among the plurality of components is operating,

the method further comprising:

taking, with the temperature sensor, during operation of the second stage, a third snapshot before the end of a third predetermined time after a start of operation of the second stage;

determining, with the controller, a rate of change of the supply temperature during the operation of second stage based on a temperature differential between the second and third snapshots and a time differential between the second and third snapshots; and

determining, with the processor, a rate of change per kW of the supply temperature during operation of the first and second stages based on a temperature differential between the first and third snapshots and a power differential between the first snapshot and the combined second and third snapshots.

13. The method of claim 12 , wherein the HVAC unit is further configured to operate in a third stage that is a heating stage, the method further comprising:

changing, with the controller, the set point in the thermostat to a temperature sufficient to cause the HVAC unit to operate in the third stage in which at least a third component among the plurality of components is operating after the second stage;

taking, with the temperature and power sensors, during operation of the third stage, a fourth snapshot before the end of a fourth predetermined time after a start of operation of the third stage; and

determining, with the controller, a rate of change per kW of the supply temperature during operation of the third stage based on a temperature differential between the third snapshot and the fourth snapshot and a power differential between the combined first, second, and third snapshots and the fourth snapshot.

14. The method of claim 13 , further comprising:

determining, with the controller, a rate of change of the supply temperature per kW during operation of the combined first, second, and third stages based on a temperature differential between the first and fourth snapshots and a power differential between the first and the combined second, third, and forth snapshots.

15. The method of claim 11 , further comprising:

transmitting, with the controller, the rates of change to a sever remote from a facility where the HVAC units are located; and

comparing, with the server, the rates of change to one or more of:

a previous rate of change for the HVAC unit,

a rate of change for another HVAC unit at the same facility, and

a rate of change for another HVAC unit at a different facility.

16. The method of claim 11 , wherein the HVAC unit comprises multiple HVAC units, the method further comprising:

grouping, with the energy management system, the first and second stages for each HVAC unit of the multiple HVAC units to define a sequence of heating and cooling tests for the multiple HVAC units; and

executing, with the energy management system, the sequences of heating and cooling tests at a predetermined time.

17. The method of claim 16 , wherein the sequence of heating and cooling tests allows each HVAC unit to be tested at a different time of day.

18. The method of claim 16 , further comprising defining, with the energy management system, a schedule that allows each HVAC unit to be tested before a seasonal change.

19. The method of claim 11 , further comprising:

predicting a failure or a malfunction of the first component based on the determined rate of change of the supply temperature during operation of the first stage.

20. The method of claim 11 , further comprising:

comparing, with the controller, a power measurement from the first snapshot to a predetermined threshold; and

providing, with the controller, an indication if the power measurement is below the predetermined threshold.