AirloopHVAC:UnitarySystem uses outdoor air temperature to size water source dx cooling coils and incorrectly reports autosized supplemental heating coil capacity for CoolReheat control #9501

rraustad · 2022-06-17T00:43:39Z

Pull request overview

Fixes AirloopHVAC:UnitarySystem uses outdoor air temperature to size a water source coil and incorrectly reports autosized supplemental heating coil capacity for CoolReheat control #9497
The water-source coil capacity calculated by UnitarySystem is now correct and in sync with how the variable speed coil model calculates capacity for this coil type.
When a supplemental heating coil is present in AirloopHVAC:UnitarySystem the size of that heating coil should represent the dehumidification control type. For CoolReheat systems, the supplemental heating coil should be at least the size of the cooling coil to offset excess sensible cooling capacity.
Partially addresses UnitarySystem report for Unitary System Electricity Rate/Energy incorrect when electric, gas, multistage or desuperheater heating coils are used for the main and supplemental heating coil #9512 for gas and electric coils.

NOTE: ENHANCEMENTS MUST FOLLOW A SUBMISSION PROCESS INCLUDING A FEATURE PROPOSAL AND DESIGN DOCUMENT PRIOR TO SUBMITTING CODE

Pull Request Author

Add to this list or remove from it as applicable. This is a simple templated set of guidelines.

Reviewer

This will not be exhaustively relevant to every PR.

rraustad · 2022-06-17T00:50:50Z

This branch is a pre-cursor to other maintenance changes that require uniformity in component sizing. Some zone coil models use the zone return air temperature for coil sizing, this is not accurate since the actual zone temperature is what enters the component because the zone models draw air directly from the zone. Additionally, a new method to determine the variable-speed water source coil source temperature (i.e., outdoor temperature or water entering temperature) was implemented that is included here.

src/EnergyPlus/Autosizing/CoolingCapacitySizing.cc

@@ -140,8 +140,7 @@ Real64 CoolingCapacitySizer::size(EnergyPlusData &state, Real64 _originalValue,
                                    CoilInTemp = this->finalZoneSizing(this->curZoneEqNum).DesCoolCoilInTemp;
                                    CoilInHumRat = this->finalZoneSizing(this->curZoneEqNum).DesCoolCoilInHumRat;
                                } else {
-                                    CoilInTemp = this->finalZoneSizing(this->curZoneEqNum)
-                                                     .ZoneRetTempAtCoolPeak; // Question whether zone equipment should use return temp for sizing
+                                    CoilInTemp = this->finalZoneSizing(this->curZoneEqNum).ZoneTempAtCoolPeak;


rraustad · 2022-06-17T00:54:31Z

src/EnergyPlus/Autosizing/CoolingCapacitySizing.cc

@@ -167,6 +166,7 @@ Real64 CoolingCapacitySizer::size(EnergyPlusData &state, Real64 _originalValue,
                            if (DDNum > 0 && TimeStepNumAtMax > 0) {
                                OutTemp = state.dataSize->DesDayWeath(DDNum).Temp(TimeStepNumAtMax);
                            }
+                            if (this->dataCoolCoilType > -1) OutTemp = GetCoilSourceTempUsedForSizing(this->dataCoolCoilType, OutTemp);


Protected call to new function that mimics GetVSCoilRatedSourceTemp added 7 days ago. If a parent object (or unit test) does not set the coil type, notihng happens, and OutTemp remains unchanged.

OutTemp is only used in the CapFT equation at line 189 below.

TotCapTempModFac = CurveManager::CurveValue(state, this->dataTotCapCurveIndex, CoilInWetBulb, OutTemp);

rraustad · 2022-06-17T00:55:11Z

src/EnergyPlus/UnitarySystem.cc

@@ -1534,6 +1534,8 @@ namespace UnitarySystems {
        } else {
            state.dataHVACGlobal->DXCT = 1; // uses normal DX coil flow limits
        }
+        // sizing may need to know what type of coil is being sized
+        state.dataSize->DataCoolCoilType = this->m_CoolingCoilType_Num;


UnitarySystem sets this to mimic the sizing of the VS coil model. Currently only cooling is accounted for.

rraustad · 2022-06-17T00:56:06Z

src/EnergyPlus/UnitarySystem.cc

@@ -15211,6 +15213,9 @@ namespace UnitarySystems {
            } else {
                this->m_FirstPass = false;
            }
+            // reset the global system type flags
+            state.dataSize->ZoneEqDXCoil = false;
+            // state.dataSize->ZoneEqFanCoil = false; // not used yet


These should have been set to false, as is normally done in parent objects.

rraustad · 2022-06-17T01:16:10Z

src/EnergyPlus/Autosizing/BaseSizerWithScalableInputs.cc

+    }
+    return sourceTemp;
+}
+


This new sizing member function mimics the VS coil model function used to set the coil source temperature (e.g., OAT or entering water T). That function will need to be modified in the near future. This function sets up a method for a parent object (i.e., UnitarySystem) to gather the same information used for sizing calculations. There will obviously be more changes here as the VS coil model sizing calculations evolve.

rraustad · 2022-06-17T03:12:04Z

Diffs in DOAToPTAC_DrawReturnAir.

- Component Sizing Information, Coil:Cooling:DX:SingleSpeed, SPACE2-1 PTAC CCOIL, Design Size Gross Rated Total Cooling Capacity [W], 3079.87455
- Component Sizing Information, Coil:Cooling:DX:SingleSpeed, SPACE2-1 PTAC CCOIL, Design Size Gross Rated Sensible Heat Ratio, 0.80041
+ Component Sizing Information, Coil:Cooling:DX:SingleSpeed, SPACE2-1 PTAC CCOIL, Design Size Gross Rated Total Cooling Capacity [W], 3079.88046
+ Component Sizing Information, Coil:Cooling:DX:SingleSpeed, SPACE2-1 PTAC CCOIL, Design Size Gross Rated Sensible Heat Ratio, 0.80040
- Component Sizing Information, Coil:Cooling:DX:SingleSpeed, SPACE5-1 PTAC CCOIL, Design Size Gross Rated Total Cooling Capacity [W], 6223.85405
+ Component Sizing Information, Coil:Cooling:DX:SingleSpeed, SPACE5-1 PTAC CCOIL, Design Size Gross Rated Total Cooling Capacity [W], 6223.81921

mjwitte · 2022-06-17T13:56:21Z

This is inaccurate for zone coils since the actual coil inlet temperature is the zone temp (or zone temp mixed with outdoor air), without inclusion of lighting heat gain

Are you sure this is not stepping on the changes to let zone equipment draw from a plenum? See #8719

Myoldmopar · 2022-06-17T15:13:00Z

I'll hold from diving in until @mjwitte's comment is addressed.

rraustad · 2022-06-17T18:28:00Z

I'll put this change to which coil inlet temp to use in a different branch. That leaves only the new VS coil function in this branch.

rraustad · 2022-06-18T01:20:13Z

Are you sure this is not stepping on the changes to let zone equipment draw from a plenum? See #8719

I'm sure now

mjwitte · 2022-06-20T20:02:20Z

@rraustad Is there a defect file for this 9497?

rraustad · 2022-06-20T20:15:27Z

Yes, and no. This change is to correct the last eio diff in #9273. ZoneVSWSHP_wDOAS uses ZoneHVAC:WaterToAirHeatPump (PTUnit). I guess I could try to create one using UnitarySystem if it were necessary. When I merge this in with 9273 the diff should be gone. You want an example file to see the coil size change?

mjwitte · 2022-06-20T20:19:36Z

@rraustad I didn't understand the connection between this an #9273. I can run ZoneVSWSHP_wDOAS with the 9273 branch to see the change.

rraustad · 2022-06-20T20:22:08Z

No, you can't. You'll only see the change when UnitarySystem manages the PTUnit. I am making a defect file now.

rraustad · 2022-06-20T20:23:23Z

Are you going to merge this branch into 9273 locally to see the change?

mjwitte · 2022-06-20T20:26:15Z

No, you can't. You'll only see the change when UnitarySystem manages the PTUnit. I am making a defect file now.

Now I'm more confused. I thought that's what 9273 did (switch to UnitarySystem running the PTUnit).

Are you going to merge this branch into 9273 locally to see the change?

I wasn't planning to. I'm still misunderstanding the connections here.

mjwitte · 2022-06-20T20:31:00Z

Are you going to merge this branch into 9273 locally to see the change?

Oh, I see. Running ZoneVSWSHP_wDOAS doesn't exercise the changed code unless it's merged with 9273 so that it's actually running UnitarySystem. If you've made a Unitary idf version of this, I'll use that. Otherwise I may make one here.

rraustad · 2022-06-20T20:39:41Z

I see example file UnitarySystem_VSHeatPumpWaterToAirEquationFit. So I guess with this branch I will create a diff in that file.

mjwitte · 2022-06-20T20:42:40Z

Actually, it won't because that one isn't autosized. I'm borrowing from that to make a unitary version that is autosized.

rraustad · 2022-06-27T23:27:07Z

@mjwitte this seems like a good place to stop. 2 files had a large increase in UnitarySystem air flow to match the cooling coil air flow size. 1 had an increase in supp heater size since it was a CoolReheat application. 1 added a design-size supp heater capacity to compare to the user specified value.

5Zone_Unitary_VSDesuperheatWaterHeater
5Zone_Unitary_VSDesuperheater

- Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Supply Air Flow Rate [m3/s], 2.62064
- Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Heating Supply Air Flow Rate [m3/s], 2.62064
- Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Cooling Supply Air Flow Rate [m3/s], 2.62064
- Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size No Load Supply Air Flow Rate [m3/s], 2.62064
+ Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Supply Air Flow Rate [m3/s], 5.50017
+ Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Heating Supply Air Flow Rate [m3/s], 5.50017
+ Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Cooling Supply Air Flow Rate [m3/s], 5.50017
+ Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size No Load Supply Air Flow Rate [m3/s], 5.50017
- Component Sizing Information, Fan:VariableVolume, SUPPLY FAN 1, Design Size Maximum Flow Rate [m3/s], 2.62064
+ Component Sizing Information, Fan:VariableVolume, SUPPLY FAN 1, Design Size Maximum Flow Rate [m3/s], 5.50017
  Component Sizing Information, COIL:COOLING:DX:VARIABLESPEED, MAIN COOLING COIL 1, Design Size Rated Total Cooling Capacity [W], 53882.19699
  Component Sizing Information, COIL:COOLING:DX:VARIABLESPEED, MAIN COOLING COIL 1, Design Size Rated Air Flow Rate [m3/s], 5.50017

5Zone_Unitary_HXAssistedCoil

AirLoopHVAC:UnitarySystem,
  GasHeat DXAC Furnace 1,  !- Name
  Setpoint,                !- Control Type
  ,                        !- Controlling Zone or Thermostat Location
  CoolReheat,              !- Dehumidification Control Type


  Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Nominal Cooling Capacity [W], 56749.30407
  Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Nominal Heating Capacity [W], 28151.00449
  Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Maximum Supply Air Temperature [C], 18.00000
  Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, User-Specified Maximum Supply Air Temperature [C], 80.00000
- Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Supplemental Heating Coil Nominal Capacity [W], 28151.00449
+ Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, Design Size Supplemental Heating Coil Nominal Capacity [W], 56749.30407
  Component Sizing Information, AirLoopHVAC:UnitarySystem, GASHEAT DXAC FURNACE 1, User-Specified Supplemental Heating Coil Nominal Capacity [W], 32000.00000
- Component Sizing Information, Coil:Heating:Fuel, HUMIDISTAT REHEAT COIL 1, Design Size Nominal Capacity [W], 28151.00449
+ Component Sizing Information, Coil:Heating:Fuel, HUMIDISTAT REHEAT COIL 1, Design Size Nominal Capacity [W], 56749.30407

Big change here same as above, 16.14 tons cooling = 193680 Btu/hr supp heating coil capacity.

UnitarySystem_MultiSpeedCoils_SingleMode

+ Component Sizing Information, Coil:Heating:Fuel, HEAT PUMP DX SUPP HEATING COIL 1, Design Size Nominal Capacity [W], 35500.00000
  Component Sizing Information, Coil:Heating:Fuel, HEAT PUMP DX SUPP HEATING COIL 1, User-Specified Nominal Capacity [W], 45000.00000

rraustad · 2022-06-28T14:32:34Z

src/EnergyPlus/UnitarySystem.cc

+            } else if (this->m_Humidistat && this->m_DehumidControlType_Num == DehumCtrlType::CoolReheat) {
+                state.dataSize->SuppHeatCap = max(this->m_DesignCoolingCapacity, this->m_DesignHeatingCapacity);
+            } else {
+                state.dataSize->SuppHeatCap = this->m_DesignHeatingCapacity;
            }


The one issue with this is that this->m_DesignHeatingCapacity is the capacity of the heating coil. For a HP in a cooling dominated climate, this is the same size as the cooling coil (heating capacity was upsized to match). So this is not the raw heating load when a HP is used. If that HP does not use CoolReheat, do we want the supplemental heating coil capacity to match the heating coil, or be sized to meet the heating load? I just ran a local test suite to see what diffs this correction would cause (i.e., using saveRawHeatingCapacity here in the else). Only 1 additional example file had a diff, the HVACTemplate-5ZoneUnitarySystem file.

Not the diff I was expecting, I thought the supp heater would have a lower capacity. That means this HP is not meeting the heating load?

HVACTemplate-5ZoneUnitarySystem diff:

Ah, the UnitarySystem finds cooling = 5kW and heating = 10kW. The WSHP has it's own sizing routine and finds cooling = 5kW and sets heating cap = cooling cap. The UnitarySystem calls over to the WSHP and gets the coil sizes. So the 10 kW was the original heating capacity. Just another never ending thing that needs fixing. I'll post an issue.

I'm surprised we can size anything in E+. Here's a single-zone HP of 5 kW size where total cooling = 5 kW and heating (supposedly) = 10 kW. The 5 kW HP has no problem meeting the winter design day zone load and holds Tstat temp. On the design days, the coils never exceed 3.5 kW although the cooling coil design sensible capacity is 3.8 kW, so that's close, and how these coils were sized. Is heating performance just luck? The heating size = 10 kW comes from a capacity calculation using the cooling design flow (e.g., main system flow = max(coolingFlow, heatingFlow) and a system Central Heating Design Supply Air Temperature = 50 C (Sizing:Zone SAT also = 50 C). The cooling air flow is 5 times larger than heating. At 5x flow, you don't need 50 C SAT to meet the zone heating load. That could be just dumb luck that the cooling size worked here. How often is the peak cooling load similar to the heating load? It seems HP sizing based on geography is a little more complex than first thought.

System heating flows for Sys 4 from 2 design days shown in eplusssz.csv and zone air flow from epluszsz.csv:

When I request the system heating flow rate in UnitarySystem this is what I get. Someone's messin with me.

rraustad · 2022-06-29T13:25:29Z

src/EnergyPlus/Autosizing/HeatingCapacitySizing.cc

+                    if (this->dataFlowUsedForSizing > 0.0) {
+                        DesVolFlow = this->dataFlowUsedForSizing;
+                    }
+                } else if (this->zoneEqSizing(this->curZoneEqNum).HeatingCapacity) {


UnitarySystem now sets the flag in the HeatingCoils::SimulateHeatingCoilComponents call so that sizing knows this is a supplemental heating coil. With that information UnitarySystem can set the capacity of the coil according to whether CoolReheat dehumidification control is used.

rraustad · 2022-06-29T13:26:14Z

src/EnergyPlus/DataSizing.cc

@@ -322,6 +322,8 @@ void resetHVACSizingGlobals(EnergyPlusData &state,
    state.dataSize->DataCoilSizingAirInHumRat = 0.0;
    state.dataSize->DataCoilSizingAirOutTemp = 0.0;
    state.dataSize->DataCoilSizingAirOutHumRat = 0.0;
+    state.dataSize->DataCoolCoilType = -1;
+    state.dataSize->DataCoolCoilIndex = -1;


Needed to call over to VS coils to get T for CapFT curve.

rraustad · 2022-06-29T13:26:43Z

src/EnergyPlus/UnitarySystem.cc

@@ -1534,6 +1534,9 @@ namespace UnitarySystems {
        } else {
            state.dataHVACGlobal->DXCT = 1; // uses normal DX coil flow limits
        }
+        // sizing may need to know what type of coil is being sized
+        state.dataSize->DataCoolCoilType = this->m_CoolingCoilType_Num;
+        state.dataSize->DataCoolCoilIndex = this->m_CoolingCoilIndex;


This information is set only in UnitarySystem.

rraustad · 2022-06-29T13:33:44Z

src/EnergyPlus/UnitarySystem.cc


        // STEP 4: set heat pump coil capacities equal to greater of cooling or heating capacity
-        if (this->m_HeatPump) { // if a heat pump, use maximum values and set main air flow and capacity variables
+        // if a heat pump, use maximum values and set main air flow and capacity variables
+        if (this->m_HeatPump && (state.dataSize->CurZoneEqNum == 0 || !isWSVarSpeedCoolCoil)) {


Don't need CurZoneEqNum == 0 here. Will need to reevaluate this logic when this branch gets merged with #9273 so will address that then.

rraustad · 2022-06-29T13:34:24Z

src/EnergyPlus/UnitarySystem.cc

+                EqSizing.DesCoolingLoad = max(EqSizing.DesCoolingLoad, EqSizing.DesHeatingLoad);
+                EqSizing.DesHeatingLoad = EqSizing.DesCoolingLoad;
+                state.dataSize->DXCoolCap = EqSizing.DesCoolingLoad;
+            }


The WS VS coil retains the cooling/heating coil size even though it's a heat pump.

rraustad · 2022-06-29T13:36:30Z

testfiles/CMakeLists.txt

@@ -616,6 +616,7 @@ add_simulation_test(IDF_FILE UnitarySystem_TwoStageDXWithHumidityControl.idf EPW
 add_simulation_test(IDF_FILE UnitarySystem_VSCoolingCoil.idf EPW_FILE USA_IL_Chicago-OHare.Intl.AP.725300_TMY3.epw)
 add_simulation_test(IDF_FILE UnitarySystem_VSHeatPumpWaterToAirEquationFit.idf EPW_FILE USA_IL_Chicago-OHare.Intl.AP.725300_TMY3.epw)
 add_simulation_test(IDF_FILE UnitarySystem_WaterCoils_wMultiSpeedFan.idf EPW_FILE USA_IL_Chicago-OHare.Intl.AP.725300_TMY3.epw)
+add_simulation_test(IDF_FILE UnitarySystem_ZoneVSWSHP_wDOAS.idf EPW_FILE USA_CO_Golden-NREL.724666_TMY3.epw)


There were no WS VS coils wrapped in a UnitarySystem.

rraustad · 2022-06-29T13:44:25Z

src/EnergyPlus/UnitarySystem.cc

@@ -7461,7 +7523,7 @@ namespace UnitarySystems {

        if ((CoilType_Num == DataHVACGlobals::Coil_HeatingGasOrOtherFuel) || (CoilType_Num == DataHVACGlobals::Coil_HeatingElectric)) {
            HeatingCoils::SimulateHeatingCoilComponents(
-                state, CompName, FirstHVACIteration, _, this->m_SuppHeatCoilIndex, _, _, this->m_FanOpMode, this->m_SuppHeatPartLoadFrac);
+                state, CompName, FirstHVACIteration, _, this->m_SuppHeatCoilIndex, _, true, this->m_FanOpMode, this->m_SuppHeatPartLoadFrac);


In addition to being used in sizing this flag also selects the report variable in ReportHeatingCoil. Probably should eliminate the Supp variable here.

if (coilIsSuppHeater) { state.dataHVACGlobal->SuppHeatingCoilPower = heatingCoil.ElecUseLoad; } else { state.dataHVACGlobal->ElecHeatingCoilPower = heatingCoil.ElecUseLoad; }

Well, can't get rid of that variable. These are used in Parent objects to sum the power for each component. So if there is a main heating coil and supplemental heating coil, these need to be kept separate.

rraustad · 2022-06-30T04:31:57Z

This is finally ready for review.

mjwitte

Ok, we're near the finish line (after about 20 laps around the track).
Unit tests run locally - check.
Sizing for Unitary-ZoneVSWSHP_wDOAS now aligns with ZoneVSWSHP_wDOAS - check.
CI diffs for 5Zone_Unitary_HXAssistedCoil show reheat coil cap matches cooling coil cap - check
CI diffs for UnitarySystem_MultiSpeedCoils_SingleMode, now the supp heat coil reports a design size that aligns with the UnitarySystem heating capacity (this has no reheat) - check.

The only things left are to clear up the build warning and make sure the top comment description aligns with the final answer here.

rraustad · 2022-06-30T17:44:01Z

…7-UnitarySystem-VS-coil-sizing

rraustad · 2022-06-30T18:50:55Z

I went over the issue and PR descriptions last night. Reading again I don't see any missing discussion. Each of the 4 bullets is addressed in this PR.

mjwitte · 2022-06-30T21:50:23Z

Thanks @rraustad ! Merging.

Clean up

b366692

rraustad added the Defect Includes code to repair a defect in EnergyPlus label Jun 17, 2022

rraustad changed the title ~~Clean up~~ AirloopHVAC:UnitarySystem uses oat to size water source dx cooling coils Jun 17, 2022

rraustad requested a review from Myoldmopar June 17, 2022 00:45

rraustad changed the title ~~AirloopHVAC:UnitarySystem uses oat to size water source dx cooling coils~~ AirloopHVAC:UnitarySystem uses outdoor air temperature to size water source dx cooling coils Jun 17, 2022

rraustad commented Jun 17, 2022

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ZoneHVAC:PackagedTerminalAirConditioner transition to UnitarySystem #9273

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Revert change to ZoneRetTempAtCoolPeak

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And revert unit test

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rraustad added 3 commits June 27, 2022 11:28

Revise supp heating coil sizing logic

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Revision 2 to supp heat sizing method

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Revision 3 to supp heat sizing method

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rraustad commented Jun 28, 2022

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rraustad added 3 commits June 28, 2022 23:28

More revisions and new test file

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Revert changes to VS coil

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Clang format and stray reverts

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rraustad commented Jun 29, 2022

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rraustad mentioned this pull request Jun 29, 2022

Inccorret declaration of dataIsDXCoil variable in BaseSizer #9511

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Add unit test

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rraustad mentioned this pull request Jun 30, 2022

Addressed Inccorret declaration of dataIsDXCoil variable in BaseSizer #9514

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rraustad added 2 commits June 30, 2022 13:54

Clean build warning

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Merge branch 'develop' of https://github.com/NREL/EnergyPlus into 949…

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…7-UnitarySystem-VS-coil-sizing

mjwitte merged commit 34419b3 into develop Jun 30, 2022

mjwitte deleted the 9497-UnitarySystem-VS-coil-sizing branch June 30, 2022 21:50

AirloopHVAC:UnitarySystem uses outdoor air temperature to size water source dx cooling coils and incorrectly reports autosized supplemental heating coil capacity for CoolReheat control #9501

AirloopHVAC:UnitarySystem uses outdoor air temperature to size water source dx cooling coils and incorrectly reports autosized supplemental heating coil capacity for CoolReheat control #9501

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