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fix Super high COP in VRFFluidTCtrl model #10752

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fix Super high COP in VRFFluidTCtrl model #10752

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@yujiex yujiex commented Sep 19, 2024

Pull request overview

1. Fix of the super high COP problem

The following shows the distribution of heating and cooling COP before vs after the fix. For display purpose, the COP=0 points are removed.
image
eplusout_defect_output_1025.csv
eplusout_fix_1025.csv

COP is calculated as this->TotalHeatingCapacity divided by this->ElecHeatingPower and other auxiliary power.

this->OperatingHeatingCOP = (this->TotalHeatingCapacity) /
                            (this->ElecHeatingPower + this->CrankCaseHeaterPower + this->EvapCondPumpElecPower + this->DefrostPower);

this->ElecHeatingPower is calculated as compressor power and outdoor fan power this->ElecHeatingPower = this->Ncomp + this->OUFanPower;

The following shows how this->TotalHeatingCapacity and this->TotalCoolingCapacity are calculated in FluidTCtrl model and the curve-based model. This has led me to believe the super high COP is cause by numerator not multiplying the CyclingRatio term. But it's NOT because of this.

// FluidTCtrl model
    this->TotalCoolingCapacity = TotalCondCoolingCapacity * CoolingPLR;
    this->TotalHeatingCapacity = TotalCondHeatingCapacity * HeatingPLR;
// curve-based model
    vrf.TotalCoolingCapacity = TotalCondCoolingCapacity * CoolingPLR * CyclingRatio;
    vrf.TotalHeatingCapacity = TotalCondHeatingCapacity * HeatingPLR * CyclingRatio;

heating COP fix

Even if here the cycling ratio is not multiplied, when plotting the "VRF Heat Pump Total Heating(Cooling) Rate" against cycling ratio, there's actually a positive linear relationship. However, the linear relationship between heating-rate and cycling ratio has a noticeable intercept, while the intercept for the compressor power and cycling ratio line is near zero. This would mean, when cycling ratio is very small, numerator in heating COP will be non-zero while the denominator approaches zero (compressor power and fan power both go to zero), the heating COP will thus blow up.

image

Comparing with v23.1, this non-zero intercept is also present in the heat pump heating rate and cycling ratio relationship.
image

However, it didn't blow up as the outdoor unit fan power is always constant and not cycling with the coil even if the "Supply Air Fan Operating Mode Schedule Name" points to a constant-zero schedule (fan always cycles with coil). The following shows the comparison of heatingCOP vs cycling ratio relationship between current develop and v23-1. We can see when zoomed in, they both have the exponential decay pattern.

image

To fix it, the Ncomp multiplying by cycling ratio is moved to inside of the VRFOU_CalcCompH function. Previously (in the develop branch), Ncomp is calculated inside the function by multiplying the rated capacity and the power performance curve value, and the cycling ratio is multiplied to the calculated Ncomp after the VRFOU_CalcCompH. However, since the heating demand in VRFOU_CalcCompH involves the compressor heat release (Q_evap_req = TU_load + Pipe_Q - Ncomp;), if here Ncomp didn't multiply by cycling ratio, than the compressor heat release is overestimated, leading to an underestimation of the heating demand Q_evap_req, as a result, the computed cycling ratio will also be smaller than it should be, creating a mismatch between the cycling ratio and the heating rate. Whether the cycling ratio is multiplied inside or after VRFOU_CalcCompH will matter in the cycling ratio calculation in heating mode, but not in cooling mode as Ncomp was not in the demand calculation there.

After applied this fix, this is how the heating rate, compressor power, and COP look relative to cycling ratio

image

cooling COP fix

The cooling COP didn't go up as high as heating one but still with a maximum of 150+, which is too high to be realistic. The reason for the high cooling COP is likely the non-linearity between heat pump cooling rate and the cycling ratio when cycling ratio is very small.

image

In the cycling ratio calculation, the code attempts to match the demand and capacity. If the they cannot match because the capacity is too large, then it will cycle and the cycling ratio is calculated as

Cap_Eva0 = (TU_load + Pipe_Q) * C_cap_operation; // <- demand
Cap_Eva1 = this->CoffEvapCap * this->RatedEvapCapacity *
            CurveValue(state, this->OUCoolingCAPFT(CounterCompSpdTemp), T_discharge, T_suction); // <- capacity
CyclingRatio = Cap_Eva0 / Cap_Eva1;

When the cycling ratio is very small, this adjustment term C_cap_operation exhibits a exponential decay pattern as well and quickly goes to 0 as cycling ratio drops, which seems to be the cause of the non-linear pattern in the heat pump cooling rate-cycling ratio relationship (the following plot is in the develop branch, using debug prints to export value of cyclingRatio and C_cap_operation after line 11486 (Q_h_OU *= CyclingRatio; line)). The 6 subfigures on the right show how the 6 input variables vary with cycling ratio. h_comp_in_real, P_evap_reql, and T_comp_in_rate show some shoot up very high for when the cycling ratio is low.

image

after removing this multiplier, the cooling rate non-linear behavior is gone and COP vs cycling ratio plot is like the following

image

Note that in version 23.1, the cycling ratio is like the following

image

2. Fix of the refrigerant warning

The issue is originated from the change of this line in PR#10416 the following line. The intention is to

image

The intention of the change is to impose a lower bound in solving for an evaporating temperature when the heating load is small. Such a lower bound is necessary as otherwise, in many time steps when the system is cycling, the OU evaporating temperature will be -72C, which is too low to be feasible. However, using the value of the input field "Variable Evaporating Temperature Minimum for Indoor Unit" as the lower bound will trigger a bunch of refrigerant warnings.

To fix the refrigerant flow problem, it is observed that the following line might have been a mistake CapMinPe = min(Pdischarge - this->CompMaxDeltaP, RefMinPe);. Pdischarge is the compressor discharge pressure,
this->CompMaxDeltaP is the maximum compressor pressure rise. Then Pdischarge - this->CompMaxDeltaP is minimum compressor suction pressure considering pressure rise bound. The RefMinPe is minimum refrigerant evaporating pressure, which is a pressure lower bound considering physical feasibility. CapMinPe should be no less than both of them, so it should be max of them, not min.

In the code base, there are three places where CapMinPe is calculated (shown in the following). Two of them are max, one is min, hinting that the min might be a bug.

image

After imposing the right pressure bound, the refrigerant warnings are mostly gone. The following are the eplusout.err files from the develop and the feature branch. A difference can be seen just from the file size.

fix_eplusout.err.zip
develop_eplusout.err.zip

3. Fix of the recurring warning issue

The warning message keep showing up is the non-recurring warning (which should only be shown once or a few times).

The excessive amount of warning is produced by this chunk of code. The condition this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest decides whether it prints this warning. The right hand side of the inequality is 1, while the left hand side overflows to negative at some point to -2147450880. From then on, the condition just keeps evaluates to true and the warning keeps showing up. It overflows as it is not a counter, but a sum of all previous counter values. This makes it get large very quickly. When it overflows, the counter value of df->SatErrCountGetSupHeatDensityRefrig is 65536. This this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest is 1 + 2 + ... + 65536, which overflowed.

++df->SatErrCountGetSupHeatDensityRefrig;
// send warning
this->errors[(int)RefrigError::SatSupDensity].count += df->SatErrCountGetSupHeatDensityRefrig;
// send warning
if (this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest) {
    ShowWarningMessage(
        state,
        format("{}: Refrigerant [{}] is saturated at the given conditions, saturated density at given temperature returned. **",
                routineName,
                this->Name));
    ShowContinueError(state, fmt::format("...Called From:{}", CalledFrom));
    ShowContinueError(state, format("Refrigerant temperature = {:.2R}", Temperature));
    ShowContinueError(state, format("Refrigerant pressure = {:.0R}", Pressure));
    ShowContinueError(state, format("Returned Density value = {:.3R}", saturated_density));
    ShowContinueErrorTimeStamp(state, "");
}

4. Cooling Coil Type [1] IP to SI unit conversion warning

The warning is produced because the code assumes there is a unit of measure inside the bracket and will attempt to perform unit conversion. Here this is a categorical variable and should not attempt to do unit conversion, so [] is not appropriate. The problem if fixed by changing the "[]" into "()" in this "Cooling Coil Type [1]".

Regression diffs

Table big diff and Table string diffs

There are 733 files have "ColumnHeadingDifference", leading to table big diffs and string diffs. This is caused by changing "Cooling Coil Type [1]" to "Cooling Coil Type (1)" in this feature branch. The diffs are expected.

meter diff

Meter diff happens in test idf "VariableRefrigerantFlow_FluidTCtrl_5Zone", in the following two fields.

  • Electricity:Facility
  • Electricity:HVAC
    The meter diff is caused by this change. The changes here will cause differences in compressor power, which will lead to changes in Electricity:HVAC and Electricity:Facility.
    image

eso diff

in US+SF+CZ4A+hp+crawlspace+IECC_2006_VRF, VariableRefrigerantFlow_FluidTCtrl_5Zone, and VariableRefrigerantFlow_FluidTCtrl_HR_5Zone, the following fields have eso diffs

  • VRF HEAT PUMP:VRF Heat Pump Total Cooling Rate
  • VRF HEAT PUMP:VRF Heat Pump Total Heating Rate
  • VRF HEAT PUMP:VRF Heat Pump Heating Electricity Rate
  • VRF HEAT PUMP:VRF Heat Pump Heating Electricity Energy
  • VRF HEAT PUMP:VRF Heat Pump Compressor Electricity Rate
  • VRF HEAT PUMP:VRF Heat Pump Outdoor Unit Evaporating Temperature

These diffs are expected as the numerator of the COP term (heating/cooling output) is changed in this feature: it is multiplied by the cycling ratio now. The changes in COP and heating cooling rate are both expected. Changes in Outdoor Unit Evaporating Temperature is due to the correction in refrigerant pressure lower bound, which is used in calculation of OU evaporating temperature. Heating electricity rate and energy difference happen in 1/21. Heating electricity rate is the sum of compressor power and outdoor unit fan power. As a result of the changing MinOutdoorUnitTe argument from max(this->IUEvapTempLow, CapMinTe) to CapMinTe in function VRFOU_CalcCompH, compressor power will change. So diffs in heating electricity rate is also expected.

err diffs

11 files have error diffs. This is because the following warning is removed as a result of the column header change of "Cooling Coil Type".

** Warning ** Unable to find a unit conversion from Cooling Coil Type [1] into IP units

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

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@yujiex yujiex added the Defect Includes code to repair a defect in EnergyPlus label Sep 19, 2024
@yujiex yujiex self-assigned this Sep 19, 2024
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⚠️ Regressions detected on macos-14 for commit f4c30c9

Regression Summary
  • ESO Big Diffs: 3

this->TotalCoolingCapacity = TotalCondCoolingCapacity * CoolingPLR;
this->TotalHeatingCapacity = TotalCondHeatingCapacity * HeatingPLR;
this->TotalCoolingCapacity = TotalCondCoolingCapacity * CoolingPLR * CyclingRatio;
this->TotalHeatingCapacity = TotalCondHeatingCapacity * HeatingPLR * CyclingRatio;
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OK, I can see this one being missed because it's multiplied by PLR and looked correct at first glance. If COP came back in line then it's likely that all the electricity reports are correctly adjusting for cycling. Although it's not a given, because things like defrost, cranckcase heater and evap condenser pump power are small compared to compressor power, and are most likely 0 in the test files. I would check those. What else might have been missed? What happens to piping losses during cycling? What about something like compressor speed? should that also be adjusted by CyclingRatio?

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Crankcase heater seems to have considered cycling

        VRFRTF = min(1.0, (CyclingRatio / PartLoadFraction));
...
        this->CrankCaseHeaterPower = this->CCHeaterPower * (1.0 - VRFRTF);

Defrost seems to have its own "runtime fraction", the FractionalDefrostTime:

                    this->DefrostPower = DefrostEIRTempModFac * (this->HeatingCapacity / 1.01667) * FractionalDefrostTime;

                } else { // Defrost strategy is resistive
                    this->DefrostPower = this->DefrostCapacity * FractionalDefrostTime;
                }

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Crankcase heater power looks good. I think defrost power needs a CyclingRatio term. FractionalDefrostTime is the defrost time for a full time step. If the system doesn't run that time step (i.e., CyclingRatio = 0.000000001) then DefrostPower should be 0. You can check FractionalDefrostTime and see that it's a function of OA humidity ratio and has nothing to do with PLR or CyclingRatio. Of course you have to check my thinking before doing anything.

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I think you're right. FractionalDefrostTime is either from the user input or from OutdoorCoildw. It should probably multiply by cycling ratio.

For this->EvapCondPumpElecPower term, since the FluidTCtrl model doesn't have the "Evaporative Condenser Pump Rated Power Consumption" field like the curve-based VRF, this term is always 0.

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⚠️ Regressions detected on macos-14 for commit 2ef0177

Regression Summary
  • MTR Big Diffs: 10
  • Table Big Diffs: 13
  • Table String Diffs: 13
  • ESO Big Diffs: 8

Yujie Xu added 2 commits September 20, 2024 13:55
so that when the outdoor conditions cause a non-zero defrost power, AND the
system if off, defrost power would be set to zero.
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⚠️ Regressions detected on macos-14 for commit 038ba0e

Regression Summary
  • ESO Big Diffs: 3
  • Table Big Diffs: 4
  • Table String Diffs: 4
  • MTR Big Diffs: 2

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⚠️ Regressions detected on macos-14 for commit 2df905f

Regression Summary
  • ESO Big Diffs: 3
  • Table Big Diffs: 4
  • Table String Diffs: 4
  • MTR Big Diffs: 2

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⚠️ Regressions detected on macos-14 for commit 3dfc67e

Regression Summary
  • ESO Big Diffs: 3

Pdischarge is the compressor discharge pressure,
this->CompMaxDeltaP is the maximum compressor pressure rise
Pdischarge - this->CompMaxDeltaP is minimum compressor suction pressure

RefMinPe is minimum refrigerant evaporating pressure

These two terms are both lower bounds of the suction pressure

CapMinPe should be no less than both of them, so CapMinPe should be max of the
two LB, not min
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⚠️ Regressions detected on macos-14 for commit 1564bc2

Regression Summary
  • ESO Big Diffs: 3
  • MTR Big Diffs: 1
  • Table Big Diffs: 1

}
// adjust defrost power based on RTF
vrf.DefrostPower *= VRFRTF;
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This looks correct.

@@ -11592,7 +11591,8 @@ void VRFCondenserEquipment::CalcVRFCondenser_FluidTCtrl(EnergyPlusData &state, c
Tdischarge = this->refrig->getSatTemperature(state, max(min(Pdischarge, RefPHigh), RefPLow), RoutineName);

// Evaporative capacity ranges_Min
CapMinPe = min(Pdischarge - this->CompMaxDeltaP, RefMinPe);
// suction pressure lower bound need to be no less than both terms in the following
CapMinPe = max(Pdischarge - this->CompMaxDeltaP, RefMinPe);
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This looks correct. Not sure why this didn't show up during the original model develolpment.

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Yeah, I'm surprised as well.

@@ -12237,6 +12236,7 @@ void VRFCondenserEquipment::CalcVRFCondenser_FluidTCtrl(EnergyPlusData &state, c
this->ElecHeatingPower = 0;
}
this->VRFCondRTF = VRFRTF;
this->DefrostPower *= VRFRTF;
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This looks correct. A plot of DefrostPower vs RTF or CyclingRatio would show it's working.

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This is a plot of heat pump defrost power vs cycling ratio

image

When the defrost power is non-zero, it is proportional to cycling ratio

The output file is here:
eplusout_defrost_vs_cyclingRatio.xlsx

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Why is defrost electricity so small? at 6 E -9

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I used this test file. Its "Resistive Defrost Heater Capacity" is 0.0000001
US+SF+CZ5B+hp+slab+IECC_2021_VRFPhysics_v2_hrdsize_V2420.expidf.zip

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This branch looks good now. I looked at fix_eplusout.err.zip and see this warning. Why is OutputReportTabular looking to convert a cooling coil type to IP units? This is probably a FluidTCtrl cooling coil. You could fix that here or file an issue.

** Warning ** Unable to find a unit conversion from Cooling Coil Type [1] into IP units

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rraustad commented Sep 25, 2024

@yujiex these warnings (develop_eplusout.err.zip) are set up as recurring warnings so that the err file does not contain thousands of messages. However, this file does contain thousands of messages (300,000 warnings). Can you please investigate, either here or a different branch.

int RefrigErrorLimitTest = 1; // how many times error is printed with details before recurring called

++df->SatErrCountGetSupHeatDensityRefrig;
// send warning
this->errors[(int)RefrigError::SatSupDensity].count += df->SatErrCountGetSupHeatDensityRefrig;
// send warning
if (this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest) {
    ShowWarningMessage(

** Warning ** RefrigProps::getSupHeatDensity: Refrigerant [R410A] is saturated at the given conditions, saturated density at given temperature returned. **
**   ~~~   ** ...Called From:VRFOU_CapModFactor
**   ~~~   ** Refrigerant temperature = -3.55
**   ~~~   ** Refrigerant pressure = 962140
**   ~~~   ** Returned Density value = 27.216
**   ~~~   **  Environment=ANNUAL, at Simulation time=01/03 16:50 - 17:00

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yujiex commented Sep 25, 2024

Unable to find a unit conversion from Cooling Coil Type [1] into IP units

Thanks for noticing this. I will fix it here too

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yujiex commented Sep 25, 2024

@yujiex these warnings (develop_eplusout.err.zip) are set up as recurring warnings so that the err file does not contain thousands of messages. However, this file does contain thousands of messages (300,000 warnings). Can you please investigate, either here or a different branch.

int RefrigErrorLimitTest = 1; // how many times error is printed with details before recurring called

++df->SatErrCountGetSupHeatDensityRefrig;
// send warning
this->errors[(int)RefrigError::SatSupDensity].count += df->SatErrCountGetSupHeatDensityRefrig;
// send warning
if (this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest) {
    ShowWarningMessage(

** Warning ** RefrigProps::getSupHeatDensity: Refrigerant [R410A] is saturated at the given conditions, saturated density at given temperature returned. **
**   ~~~   ** ...Called From:VRFOU_CapModFactor
**   ~~~   ** Refrigerant temperature = -3.55
**   ~~~   ** Refrigerant pressure = 962140
**   ~~~   ** Returned Density value = 27.216
**   ~~~   **  Environment=ANNUAL, at Simulation time=01/03 16:50 - 17:00

Good point. I will make it recurring warnings

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⚠️ Regressions detected on macos-14 for commit 6bcb300

Regression Summary
  • Table Big Diffs: 733
  • Table String Diffs: 733
  • ERR: 11
  • ESO Big Diffs: 3
  • MTR Big Diffs: 1

the error message counter is a sum of all previous counter values
it overflows to negative
non-recurring warning keeps showing up after the overflow
use the counter, not the sum of counter in the predicate
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yujiex commented Sep 25, 2024

@rraustad I've investigated the two issues

SI to IP unit conversion warning

I fixed the warning of "unit conversion from Cooling Coil Type [1] into IP units", by changing the [] to () in the column header "Cooling Coil Type [1]". The warning is produced because the code assumes there is a unit of measure inside the bracket and will attempt to perform unit conversion. Here this is a categorical variable and should not attempt to do unit conversion, so [] is not appropriate. It is changed to () per suggestion from @JasonGlazer

recurring warning shows too many times

I also figured out the reason for the recurring warning message not showning as recurring. The messages keeps showing up is not produced by the ShowRecurringWarningErrorAtEnd, but by the following non-recurring part. The condition this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest decides wiether it will produce this warning. The right hand side of the inequality is 1, the left hand side overflows to negative at some point to -2147450880, and from then on, the condition just keeps evaluates to true and the warning keeps showing up. It overflows as it is not a counter, but a sum of all previous counter values. When it overflows, the counter value of df->SatErrCountGetSupHeatDensityRefrig is 65536. This this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest is 1 + 2 + ... + 65536, which overflowed.

I believe changing the condition to just if (df->SatErrCountGetSupHeatDensityRefrig <= df->RefrigErrorLimitTest) will solve the problem

++df->SatErrCountGetSupHeatDensityRefrig;
// send warning
this->errors[(int)RefrigError::SatSupDensity].count += df->SatErrCountGetSupHeatDensityRefrig;
// send warning
if (this->errors[(int)RefrigError::SatSupDensity].count <= df->RefrigErrorLimitTest) {
    ShowWarningMessage(
        state,
        format("{}: Refrigerant [{}] is saturated at the given conditions, saturated density at given temperature returned. **",
                routineName,
                this->Name));
    ShowContinueError(state, fmt::format("...Called From:{}", CalledFrom));
    ShowContinueError(state, format("Refrigerant temperature = {:.2R}", Temperature));
    ShowContinueError(state, format("Refrigerant pressure = {:.0R}", Pressure));
    ShowContinueError(state, format("Returned Density value = {:.3R}", saturated_density));
    ShowContinueErrorTimeStamp(state, "");
}

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⚠️ Regressions detected on macos-14 for commit 75dc8b3

Regression Summary
  • Table Big Diffs: 733
  • Table String Diffs: 733
  • ERR: 11
  • ESO Big Diffs: 3
  • MTR Big Diffs: 1

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⚠️ Regressions detected on macos-14 for commit 4943094

Regression Summary
  • Table Big Diffs: 733
  • Table String Diffs: 733
  • ERR: 11
  • ESO Big Diffs: 3
  • MTR Big Diffs: 1

@yujiex yujiex added this to the EnergyPlus 25.1 milestone Sep 30, 2024
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github-actions bot commented Oct 1, 2024

⚠️ Regressions detected on macos-14 for commit ff2a4ba

Regression Summary
  • Table Big Diffs: 733
  • Table String Diffs: 733
  • ERR: 11
  • ESO Big Diffs: 3
  • MTR Big Diffs: 1

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github-actions bot commented Oct 8, 2024

⚠️ Regressions detected on macos-14 for commit b617815

Regression Summary
  • Table Big Diffs: 735
  • Table String Diffs: 735
  • ERR: 11
  • ESO Big Diffs: 3
  • MTR Big Diffs: 1

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yujiex commented Oct 18, 2024

The fix for the high COP part (#10751) might have some problem. Let me investigate some more. Please hold off on reviewing. Thanks.

because the demand is roughly Q_evap_req = TU_load + Pipe_Q - Ncomp (multiplied
by an adjustment factor C_cap_operation). Ncomp is an input-ouptut variable of
the function. Previously Cycling ratio is multiplied outside of VRFOU_CalcCompH
after the function has computed Ncomp. However, this will lead to very small
cycling ratio non-compatible with the demand as the demand is underestimated
because of the Ncomp (in reality it should not be this large, it should be
Ncomp * CyclingRatio). This doesn't matter on the cooling side as Ncomp is not
involved in the demand calculation there.
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⚠️ Regressions detected on macos-14 for commit 7f50e74

Regression Summary
  • Table Big Diffs: 735
  • Table String Diffs: 735
  • ERR: 11
  • ESO Big Diffs: 2
  • MTR Big Diffs: 2

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⚠️ Regressions detected on macos-14 for commit 236148c

Regression Summary
  • Table Big Diffs: 735
  • Table String Diffs: 735
  • ERR: 12
  • EIO: 1
  • ESO Big Diffs: 4
  • MTR Big Diffs: 2

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@yujiex it has been 16 days since this pull request was last updated.

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