To achieve ambitious decarbonization goals it is critical that buildings operate to their full potential. Commercial HVAC systems, however, experience a wide range of operational faults, adversely affecting energy consumption, occupant comfort, and maintenance costs. Analytical tools such as fault detection & diagnostics (FDD) software identify and help diagnose these types of sensing, mechanical, or control-related faults. While significant energy savings has been documented for FDD, along with limited-scale studies on technical capabilities, there is a lack of empirical data on faults being reported by FDD tools. With FDD deployment accelerating significantly over the past decade there is an opportunity to gather and analyze data on commercial HVAC operational problems at an unprecedented scale. Such data could address many questions such as: [a] What faults are most commonly reported?; and [b] How does fault reporting vary by time of year and other possible drivers? A recent study into FDD fault reporting amassed the largest U.S. dataset of commercial HVAC air-side fault records, drawn from multi-year monitoring across over 60,000 pieces of HVAC equipment. The results of this study provide granular data on fault reporting for over 90 unique fault types. In this paper we provide an overview of the research process and highlight key findings and lessons learned. This study presents an extraordinary level of detail on FDD fault reporting characteristics across many climate zones and building types. Armed with these new insights, commercial building industry stakeholders can make better informed decisions when designing, configuring, and operating commercial HVAC systems.

Commercial building HVAC systems experience many sensing, mechanical, and control-related faults that increase energy consumption and impact occupant comfort. Fault detection & diagnostics (FDD) software has been demonstrated to identify and help diagnose these types of faults. Several studies have demonstrated FDD energy savings potential, but there is limited empirical data characterizing the quantity and type of faults reported by FDD tools. This paper presents results of an FDD fault reporting study, employing multi-year monitoring data for over 60,000 pieces of HVAC equipment, covering over 90 fault types, and using new metrics that we developed to characterize fault prevalence. Study results offer an unprecedented accounting of the quantity of faults reported, the most commonly occurring faults, and fault persistence. We find that 21 air handling unit (AHU) faults were reported on 20% or more AHUs in our dataset, and 18 AHU faults persisted for more than 20% of the time period covered by the data. On any given day, 40% of AHUs and 30% of air terminal units saw a reported fault of some kind. Based on in-depth analysis of these results we provide recommendations for building operators, FDD software developers, and researchers to enable more efficient commercial building operation.