Recently my wife and I completed our 'Spring Cleaning' at our home.
Dust and cob-webs in those hard to reach places that go unnoticeable during the cold gloomy days of winter had to go.
A fresh coat of paint here and there, window seals wiped clean, rugs beat, garage swept and organized...
you know the drill.
At our house the rule is that the golf clubs get put aside until all the 'Spring Cleaning Chores' are complete.
This is obviously my wife's rule...
not mine Spring Cleaning at my house would not be complete until I have serviced my air conditioning units.
Some of you that know me are laughing right now...
yes, I know how to service my own system.
Before I was a 'Solutions Provider', I turned wrenches.
I am a former licensed and trained service technician.
Getting my own hands dirty serves as a great reminder of the importance of 'Preventative Maintenance'.
During the months of March and April, our 'Preventative Maintenance Services' are in overdrive.
The task is daunting, but without proper preventative maintenance your system will not survive.
Those squelching summer temperatures are jut around the corner, and my question to you is, "Are you ready?Is your building ready?" In this edition I provide a very partial checklist you can use for your systems 'Spring Cleaning'.
I don't have the space on this page to include all the tasks that our guys use for preventative maintenance, nor do you have the time to read them.
Therefore, I will address a few various types of systems and list the most important items that need attention this spring.
But first, lets see what the U.
S.
Department of Energy says about how proper preventative maintenance is directly related to energy savings: HVAC Maintenance Procedures | Energy Savings % 1.
Adjusting the operating sequence of operations: 25-30% 2.
Cleaning Coils: 5-15% 3.
Changing Dirty Air Filters: 10-15% 4.
Removing Scale from Condenser Coils: 25-30% 5.
Adjusting Air/Fuel Ratio of Burners: 15% 6.
Cleaning Burner Assembly: 15% 7.
Removing Soot from Fire Side of Burner: 9% 8.
Eliminating Belt Slippage and Pulley Alignment: 15-20% *Information provided by U.
S.
Department of Energy Below I have broken down some of the most commonly types of air conditioning equipment into separate categories.
Under each category I listed the top 5 Air Conditioning 'To-Dos' each spring.
Detailed tasking may differ from say a commercial office building to an hospital, and a hospital may differ from the needs of a manufacturing plant.
However, this is a condensed list that applies to all AC equipment no matter the business market you are in.
If you are currently doing these, then you are ahead of the game.
If not, then call me...
my number is at the bottom.
ROOF TOP / UNITARY (DX) EQUIPMENT: 1.
Filters:Replace filters every spring.
This is one of the most basic and important maintenance no matter what the season.
I recommend replacing the filters every 3 months at a minimum.
The 40% pleated filters work best.
Forget about the Wal-Mart, blue, cheapo filter.
2.
Coils: Clean the Condenser Coils.
The most labor intensive maintenance task every spring.
The methodology behind what works the best when coil cleaning can be debated.
Stay away from acid based and pressure washers.
If using a pressure washer be sure to use a machine where the pressure can be regulated and the water volume can be increased.
Check the evaporator coil.
If the filters are changed regularly, then the evaporator coils will not require cleaning.
If dirt does make it to the evap.
coil, use a light soap solution that flushes down the condensate pan naturally.
DON'T use condenser coil cleaner on the indoor evap.
coil! 3.
Belts: Check or Replace Belts.
If more than one belt, make sure both are the correct matching size.
Adjust pulleys as needed.
Never force a belt onto the pulleys.
Take the time to loosen the pulley, slide on the belt and tighten to scale.
Always use a belt tension tool.
4.
Drain Pan: Check or Clean the condensate pan.
This little item if overlooked can be misinterpreted for a roof leak.
I have seen clogged drain pans and traps ruin an expensive computer system.
Algae drain tabs work, but use sparingly.
5.
Compressor & Motors: Check operation of all condenser fan motors, evaporator motors and compressors.
Record voltage and amperage for each motor and compressor.
Then compare your readings with the nameplate.
If the weather is warm, go ahead and put your refrigerant gauges on the compressors to check the charge.
This should be done by a licensed service technician.
The EPA and law requires it.
CHILLERS (Centrifugal) - Top 5 Items to check this Spring: 1.
Condenser Tubes: Inspect and Clean the condenser tubes.
If this task should be scheduled before warm temperatures arrive.
At SML, we schedule this work to be done in February and March.
Don't over brush.
If water treatment program is handled with care, then minimal cleaning is required.
2.
Compressor: Check operation and replace oil filter.
Check oil levels and replace or add as necessary.
Do not overfill (check O&M manual).
Send oil sample to lab for analysis.
3.
Log Sheets:Check and record a log of alltemperature readings, fluid levels, pressure readings, and flow rates.
Most manufacturing operating manuals include log sheets.
Graphic control panels, standard equipment on many chillers since 1999, eliminate the need to manually record many of these statistics.
These panels provide user-friendly logs on one large, active-matrix screen and enable operators to view multiple related parameters simultaneously on a single screen.
4.
Purge Unit:The purge unit dehydrator should also be changed regularly, preferably every three months.
Other preventive maintenance procedures that pertain to the purge unit include annual cleaning and inspecting of valves and orifices as well as draining and flushing oil and refrigerant from the purge unit shell.
5.
Refrigerant Charge Level:Check for proper refrigerant charge and perform a leak check.
AIR HANDLERS - Top 5 Items to check this Spring: 1.
Filters: As with the roof top equipment, the filters are vital to the efficiency and life cycle of the air handler.
Replace filters every spring.
I stumbled across this interesting article about filters.
Click here to read.
2.
Evaporator Motor:Check proper voltage and amperage for the evaporator motor and or motors.
Lubricate if required.
3.
Belts & Pulleys:Check or Replace Belts.
If more than one belt, make sure both are the correct matching size.
Adjust pulleys as needed.
Refer to same belt replacement instructions listed above for rooftop units.
4.
Drain Pan:Blow out condensate drain line with compressed air (DO NOT USE FREON!) and inspect piping and slope to floor drain.
5.
Bearings:Inspect shaft and bearings for wear and tight fit.
Tighten blower and bearing set screws and lock collars.
Insure internal bearing lubrication feeder lines are connected and working.
Please see O&M manual, because some bearings permanently lubricated.
CIRCULATING PUMPS -- Top 5 Items to check this Spring: 1.
Motor:Check overall operation of motor.
Check and record the voltage and compare with the nameplate.
Check and record the amperage and compare with the nameplate.
2.
Alignment:Use gauges to check for proper alignment between pump and motor.
3.
Valves:Check all valves and strainers for proper operation.
Clean strainers as necessary.
4.
Mounting:Check all mounting bolts and brackets.
Ensure the pump and motor is secure to the base plate.
5.
Gaskets:Check for any leaks around all gaskets.
COOLING TOWERS - Top 5 Items to check this Spring: 1.
Basin:Thoroughly flush and clean the cooling tower basin.
Remove any debris that could clog the strainers and pumps.
Inspect steel basin for corrosion and holes.
All sumps should be observed for accumulation of debris, condition of screens and operation drain valves.
2.
Motor:Check motor operation.
Record voltage and amperage and compare with the nameplate.
Some motors require oil.
Please see the O&M manual for further information.
3.
Belts and Bearings:Check or Replace Belts.
If more than one belt, make sure both are the correct matching size.
Adjust pulleys as needed.
Use power band belts! 4.
Water Treatment:Discuss water treatment program with the current service provider.
5.
Fill:Inspect tower fill for any breakage, deterioration or any misplaced or missing splash bars.
Look for damage to splash bar supports and fill supports.
Many of you who are technically inclined or have experience with HVAC Preventative Maintenance are screaming, "YOU FORGOT..
..
".
Yes, there is so much more like checking proper superheat, sub-cooling, vibration analysis, eddy current testing, contactor pitting...
the list is long.
However, the purpose of this edition of Mechanical Matters was to discuss some of the more important items that your equipment needs addressed every spring.
"I of course didn't show all my cards at once".
If you are interested in learning more about your systems and a custom preventative maintenance program designed for your facility, please give me a call.
At SML, we specialize in HVAC preventative maintenance every day.
We are the professionals.
"So this spring please don't forget your HVAC equipment and as always remember to leave the Mechanical Matters to us!"
Dust and cob-webs in those hard to reach places that go unnoticeable during the cold gloomy days of winter had to go.
A fresh coat of paint here and there, window seals wiped clean, rugs beat, garage swept and organized...
you know the drill.
At our house the rule is that the golf clubs get put aside until all the 'Spring Cleaning Chores' are complete.
This is obviously my wife's rule...
not mine Spring Cleaning at my house would not be complete until I have serviced my air conditioning units.
Some of you that know me are laughing right now...
yes, I know how to service my own system.
Before I was a 'Solutions Provider', I turned wrenches.
I am a former licensed and trained service technician.
Getting my own hands dirty serves as a great reminder of the importance of 'Preventative Maintenance'.
During the months of March and April, our 'Preventative Maintenance Services' are in overdrive.
The task is daunting, but without proper preventative maintenance your system will not survive.
Those squelching summer temperatures are jut around the corner, and my question to you is, "Are you ready?Is your building ready?" In this edition I provide a very partial checklist you can use for your systems 'Spring Cleaning'.
I don't have the space on this page to include all the tasks that our guys use for preventative maintenance, nor do you have the time to read them.
Therefore, I will address a few various types of systems and list the most important items that need attention this spring.
But first, lets see what the U.
S.
Department of Energy says about how proper preventative maintenance is directly related to energy savings: HVAC Maintenance Procedures | Energy Savings % 1.
Adjusting the operating sequence of operations: 25-30% 2.
Cleaning Coils: 5-15% 3.
Changing Dirty Air Filters: 10-15% 4.
Removing Scale from Condenser Coils: 25-30% 5.
Adjusting Air/Fuel Ratio of Burners: 15% 6.
Cleaning Burner Assembly: 15% 7.
Removing Soot from Fire Side of Burner: 9% 8.
Eliminating Belt Slippage and Pulley Alignment: 15-20% *Information provided by U.
S.
Department of Energy Below I have broken down some of the most commonly types of air conditioning equipment into separate categories.
Under each category I listed the top 5 Air Conditioning 'To-Dos' each spring.
Detailed tasking may differ from say a commercial office building to an hospital, and a hospital may differ from the needs of a manufacturing plant.
However, this is a condensed list that applies to all AC equipment no matter the business market you are in.
If you are currently doing these, then you are ahead of the game.
If not, then call me...
my number is at the bottom.
ROOF TOP / UNITARY (DX) EQUIPMENT: 1.
Filters:Replace filters every spring.
This is one of the most basic and important maintenance no matter what the season.
I recommend replacing the filters every 3 months at a minimum.
The 40% pleated filters work best.
Forget about the Wal-Mart, blue, cheapo filter.
2.
Coils: Clean the Condenser Coils.
The most labor intensive maintenance task every spring.
The methodology behind what works the best when coil cleaning can be debated.
Stay away from acid based and pressure washers.
If using a pressure washer be sure to use a machine where the pressure can be regulated and the water volume can be increased.
Check the evaporator coil.
If the filters are changed regularly, then the evaporator coils will not require cleaning.
If dirt does make it to the evap.
coil, use a light soap solution that flushes down the condensate pan naturally.
DON'T use condenser coil cleaner on the indoor evap.
coil! 3.
Belts: Check or Replace Belts.
If more than one belt, make sure both are the correct matching size.
Adjust pulleys as needed.
Never force a belt onto the pulleys.
Take the time to loosen the pulley, slide on the belt and tighten to scale.
Always use a belt tension tool.
4.
Drain Pan: Check or Clean the condensate pan.
This little item if overlooked can be misinterpreted for a roof leak.
I have seen clogged drain pans and traps ruin an expensive computer system.
Algae drain tabs work, but use sparingly.
5.
Compressor & Motors: Check operation of all condenser fan motors, evaporator motors and compressors.
Record voltage and amperage for each motor and compressor.
Then compare your readings with the nameplate.
If the weather is warm, go ahead and put your refrigerant gauges on the compressors to check the charge.
This should be done by a licensed service technician.
The EPA and law requires it.
CHILLERS (Centrifugal) - Top 5 Items to check this Spring: 1.
Condenser Tubes: Inspect and Clean the condenser tubes.
If this task should be scheduled before warm temperatures arrive.
At SML, we schedule this work to be done in February and March.
Don't over brush.
If water treatment program is handled with care, then minimal cleaning is required.
2.
Compressor: Check operation and replace oil filter.
Check oil levels and replace or add as necessary.
Do not overfill (check O&M manual).
Send oil sample to lab for analysis.
3.
Log Sheets:Check and record a log of alltemperature readings, fluid levels, pressure readings, and flow rates.
Most manufacturing operating manuals include log sheets.
Graphic control panels, standard equipment on many chillers since 1999, eliminate the need to manually record many of these statistics.
These panels provide user-friendly logs on one large, active-matrix screen and enable operators to view multiple related parameters simultaneously on a single screen.
4.
Purge Unit:The purge unit dehydrator should also be changed regularly, preferably every three months.
Other preventive maintenance procedures that pertain to the purge unit include annual cleaning and inspecting of valves and orifices as well as draining and flushing oil and refrigerant from the purge unit shell.
5.
Refrigerant Charge Level:Check for proper refrigerant charge and perform a leak check.
AIR HANDLERS - Top 5 Items to check this Spring: 1.
Filters: As with the roof top equipment, the filters are vital to the efficiency and life cycle of the air handler.
Replace filters every spring.
I stumbled across this interesting article about filters.
Click here to read.
2.
Evaporator Motor:Check proper voltage and amperage for the evaporator motor and or motors.
Lubricate if required.
3.
Belts & Pulleys:Check or Replace Belts.
If more than one belt, make sure both are the correct matching size.
Adjust pulleys as needed.
Refer to same belt replacement instructions listed above for rooftop units.
4.
Drain Pan:Blow out condensate drain line with compressed air (DO NOT USE FREON!) and inspect piping and slope to floor drain.
5.
Bearings:Inspect shaft and bearings for wear and tight fit.
Tighten blower and bearing set screws and lock collars.
Insure internal bearing lubrication feeder lines are connected and working.
Please see O&M manual, because some bearings permanently lubricated.
CIRCULATING PUMPS -- Top 5 Items to check this Spring: 1.
Motor:Check overall operation of motor.
Check and record the voltage and compare with the nameplate.
Check and record the amperage and compare with the nameplate.
2.
Alignment:Use gauges to check for proper alignment between pump and motor.
3.
Valves:Check all valves and strainers for proper operation.
Clean strainers as necessary.
4.
Mounting:Check all mounting bolts and brackets.
Ensure the pump and motor is secure to the base plate.
5.
Gaskets:Check for any leaks around all gaskets.
COOLING TOWERS - Top 5 Items to check this Spring: 1.
Basin:Thoroughly flush and clean the cooling tower basin.
Remove any debris that could clog the strainers and pumps.
Inspect steel basin for corrosion and holes.
All sumps should be observed for accumulation of debris, condition of screens and operation drain valves.
2.
Motor:Check motor operation.
Record voltage and amperage and compare with the nameplate.
Some motors require oil.
Please see the O&M manual for further information.
3.
Belts and Bearings:Check or Replace Belts.
If more than one belt, make sure both are the correct matching size.
Adjust pulleys as needed.
Use power band belts! 4.
Water Treatment:Discuss water treatment program with the current service provider.
5.
Fill:Inspect tower fill for any breakage, deterioration or any misplaced or missing splash bars.
Look for damage to splash bar supports and fill supports.
Many of you who are technically inclined or have experience with HVAC Preventative Maintenance are screaming, "YOU FORGOT..
..
".
Yes, there is so much more like checking proper superheat, sub-cooling, vibration analysis, eddy current testing, contactor pitting...
the list is long.
However, the purpose of this edition of Mechanical Matters was to discuss some of the more important items that your equipment needs addressed every spring.
"I of course didn't show all my cards at once".
If you are interested in learning more about your systems and a custom preventative maintenance program designed for your facility, please give me a call.
At SML, we specialize in HVAC preventative maintenance every day.
We are the professionals.
"So this spring please don't forget your HVAC equipment and as always remember to leave the Mechanical Matters to us!"