Written by Robert Baynham May
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This document has been put together to highlight why an Air Conditioning System should be regularly serviced and what we do during this essential maintenance.
It is the legal responsibility of the owner or operator of any fluorinated gas equipment which contains F-gas equivalent to 5 tonnes or more of Carbon Dioxide to ensure their systems are correctly checked and documented by an authorised company. This can include:
· Stationary refrigeration equipment
· Stationary air-conditioning equipment
· Stationary heat pumps
· Stationary fire protection equipment
· Refrigeration units of refrigerated trucks and trailers
· Electrical switch gear
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Records must be kept for 5 years on the:
· Quantity and type of gas
· Quantity and type of gas added during maintenance (leak repairs)
· Dates and results of all mandatory leak checks*
· Recorded recovery and disposal of refrigerant waste.
The environmental agency may ask to see records of the above during an inspection.
The service schedule of every system is determined by the GWP (Global Warming Potential) of the Refrigerant under charge - this calculation differs depending on the type of refrigeration and volume in the system.
*Systems Containing between 5 and 50 tonnes CO2 Equivalent require one visit per year. Systems containing between 50 and 500 tonnes CO2e require inspection every 6 months. Systems greater than 500 tonnes require quarterly inspections.
(Source: gov.uk)
During maintenance visits, all refrigerant systems are checked for basic electrical safety. This includes:
· Checks on electrical connections.
Loose electrical connections can cause electrical burning due to higher electrical resistances. This resistance dissipates power in the form of heat when current flows through it.
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· Checks on electrical components.
As found above, damaged/faulty components can also create higher electrical resistances, which again can cause electrical burning if not rectified. Upon maintenance visits, engineers will check all electrical components for signs of burning, scorching or signs of excessive heat.
· Checks on Current Draw.
All electrical systems draw current and all systems have an expected current rating. During maintenance visits, engineers will check current readings of systems and compare them to their expected current rating. If any component within the system is found to be drawing a significantly higher than expected current, this could be a clear sign of a problem. Such problems could include but restricted to; component wear/damage, wiring issues, or even low refrigerant levels. Catching these tell tale signs early could save many other system components from further unnecessary damage and save the customer significant money from emergency call out charges.
· Checks on incoming Voltage.
Whilst somewhat rare, it has been found that systems have suffered from significant damage by incorrect incoming supply voltage. If this issue isn&#;t picked up early, many costly components within a refrigeration system can become damaged. A prime example of which would be the Printed Circuit Boards within the controls of the system. During maintenance visits, these are checked by the engineer to ensure they are correct and rectified or reported before such damage occurs.
· Motor resistance checks
During maintenance visits, the resistances of motors such as those within the windings of compressors or fans are checked. Ensuring these are correct allows for the engineer to put in place preventative measures to reduce potential emergency call out costs and to reduce the disruption of unexpected cooling/heating failure.
Within all refrigerant systems there are numerous checks that are required on refrigerant components and pipework to ensure correct system performance. Whilst some of these have and will be mentioned within other sections of this document it is important within maintenance to check all available areas of the refrigerant system.
· All system pipework will be visually checked for signs of leaks or corrosion.
· All refrigerant components will be checked for correct and efficient operation.
· Temperature and pressure readings at set locations with a refrigerant system can give an engineer a clear view of how the system is performing as well as other information such as if the system has sufficient refrigerant charge. These will be taken during all maintenance visits and will allow the engineer to identify potential issues within the system before they affect complete operation. This will save the customer on emergency call out costs and potential disruptions caused by a failed system.
Refrigerant systems will often create condensation at the source of heat transfer. Within an Air Conditioning system, this will usually be created on the system&#;s indoor evaporator coil. This water therefore needs to be removed from the system. Usually, this is achieved by either gravity draining or being pumped out of the unit to a suitable drainage point. If this process is disrupted in anyway, such as blocked drainage or pump failure, this can cause water leaks from the unit. As with any water leakage, these can be both disruptive and damaging. During maintenance visits, these pumps and the correct flow of drainage is ensured and rectified if necessary.
As everyone is becoming more aware of their environmental impact, refrigerant based systems are often high on the list of priorities due to their ozone and global warming potentials. This however, although obviously a major factor for concern, is not the only environmental impact a refrigerant based system can have. An inefficient running system can also have a big impact on both the environment and a customer&#;s financial costs. During maintenance visits, engineers can advise customers on the most efficient ways of running their systems to reduce these environmental and financial costs.
Issues such as poorly lubricated motor bearings or general wear and tear of components can also create unnecessary noise pollution. These are rectified during maintenance visits where possible or if not, reported upon before they become major noise problems.
Cleaning a refrigerant based system can give customers more than they may sometimes realise;
· Firstly, an aesthetically pleasing looking system, particularly indoor evaporators within a business, gives the impression that the business cares about all areas of their business. This reflects well on said business to clients or even to staff who may come to their place of business. The levels of cleaning therefore is important and we believe that systems should be restored to a &#;as close to new as possible&#; condition during maintenance visits.
· Secondly, AC systems create condensation (as mentioned in the Condensate removal section). Where there is potential of water, there is a high potential for mound and bacterial build up. Without correct cleaning, these can build up to become foul smelling when the system operates. During maintenance, these areas of condensation build up are checked, cleaned and disinfected where necessary.
· Thirdly, the correct cleaning of systems can ensure systems run correctly and efficiently. For example, if filters or coils become blocked, effective heat transfer can not occur causing the system to run less efficiently and in extreme cases can cause system tripping and/or component damage. As such customers will likely have to pay for costly emergency call outs to rectify a simple cleaning issue.
· Finally, and often misunderstood by clients and engineers alike, is the requirement for areas of the refrigerant system to be cleaned even if they are not readily visible to anyone else but engineers who work on it. Now this may seem a pointless and time consuming exercise to some, however by ensuring complete system cleanliness, it makes even the smallest refrigerant leaks clearly visible at a much earlier stage thus reducing harmful damage to the atmosphere and system components. It also ensures that other signs of &#;leaks&#; are not overlooked as merely dirt on the system during inspections. In addition, dirt, debris, and other environmental elements can, if not cleaned regularly and effectively, cause system pipework to corrode. This not only limits the lifespan of system components, but also risks causing costly refrigerant leakage.
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