HVAC Procedures and Performance Guide

19 Procedural Guides – Job determinations and preparations, equipment inspections, system analysis and materials lists:

1. Determine job specifications
2. Determine space-load requirements
3. Determine space air-flow requirements
4. Select equipment
5. Determine type, size, and location of registers
6. Determine location for interior equipment
7. Determine type, size, and routing of duct system (including ventilation air intake and exhaust ducts)
8. Determine location for exterior equipment
9. Determine location and size of ventilation air intake
10. Determine location and size of exhaust air grill
11. Determine thermostat location
12. Determine humidistat location
13. Determine if available electrical service is adequate
14. Determine type of mounting system required for equipment (foundation, hanger, metal or wood frame)
15. Determine layout and size of refrigerant tubing
16. Determine size and routing of condensate drain
17. Determine size and routing of oil and gas piping
18. Collect job materials
19. Assist with estimating job costs

35 Procedural Guides – Installation of HVAC systems equipment and parts:

1. Prepare equipment founddation/base
2. Install anchor in concrete
3. Cut metal with portable metal saw
4. Cut carbon steel with oxyacetylene torch
5. Weld carbon steel with oxyacetylene torch and filler rod
6. Drill metal with portable electric drill
7. Install equipment vibration isolator
8. Install roof curb
9. Install self-contained unit: wall mount
10. Install self-contained unit: roof mount
11. Install self-contained unit: pad mount and through wall
12. Install air-cooled condensor package
13. Install water-cooled condensor package
14. Install air-handling unit: overhead mount
15. Install air-handling unit: floor or pad mount
16. Install humidifier: power-media type
17. Install humidifier: power-spray type
18. Install humidifier: bypass type
19. Install humidifier: steam-generator type
20. Install humidifier: self-contained through wall or ducted
21. Install duct-mounted air cleaner: filter media and electronic
22. Install ceiling-mounted air cleaner: filter media and electronic
23. Install electronic air cleaner: return-grill mount
24. Install evaporator in existing system
25. Install electric heating coil in existing system
26. Install booster fan
27. Install gas furnace
28. Install oil furnace
29. Install heat pump
30. Install gas combination heating and domestic hot water system
31. Install oil tank
32. Install OSHA protective guards on equipment
33. Install cooling tower
34. Install water pump
35. Install condensate pump

22 Procedural Guides – Modify and install duct and ventilation systems:

1. Modify existing plenum for evaporator installation
2. Modify existing duct for duct-mounted accessories installation (air cleaner or damper)
3. Prepare openings for registers, grills, and duct penetration
4. Install branch duct takeoff from main using round metal duct and fittings
5. Install duct (rectangular metal) and fittings
6. Install duct (round flexible fiberglass) and fittings
7. Install main duct (rectangular rigid fiberglass) and fittings
8. Install branch duct (flexible)
9. Install manual balancing (volume) damper
10. Install register or grill
11. Install outside air intake with screen
12. Install heat-actuated (fire) damper
13. Install barometric (draft regulator) damper
14. Install powered damper with actuator
15. Install factory-fabricated filter
16. Install flexible connector between metal duct and equipment
17. Install rigid-board duct insulation
18. Install flexible duct insulation
19. Install gas or all-fuel furnace vent
20. Install gas-furnace vent damper
21. Install vent cap
22. Install oil-furnace vent (flue)

30 Procedural Guides – Installation of piping, valves and in-line components:

1. Determine type and location of fittings and in-line components
2. Connect pipe using threaded joint
3. Install pipe using cemented joint
4. Connect tubing using compression fitting
5. Connect tubing using flare fitting
6. Connect tubing and fitting using soft-solder joint
7. Connect tubing using a swaged, brazed joint
8. Make a tubing run with offset and corner using bending tool
9. Connect aluminum tubing using solderless connector
10. Install pipe and tubing insulation and covering
11. Install refrigeration-line solenoid valve (gas or liquid)
12. Install in-line or angle hand valve
13. Install suction-line accumulator
14. Install suction/liquid-line heat exchanger
15. Install liquid receiver with a back-seating (King) valve
16. Install thermostatic expansion valve
17. Install liquid-line filter-dryer, suction-line filter, or suction-line filter-dryer
18. Install sight glass
19. Install heat-pump filter-dryer (biflow)
20. Install pressure-regulator valve (discharge bypass, crankcase pressure, and evaporator pressure)
21. Install head-pressure control valve
22. Install check valve
23. Install valve (angle charging and purging, service, or combination)
24. Install flexible vibration absorber in refrigerant line
25. Install precharged factory line set
26. Install tubing or pipe clamps and supports
27. Install evaporator condensate drain
28. Install water supply to humidifier
29. Replace four-way reversing valve
30. Replace electronic expansion valve

59 Procedural Guides – Installation and maintenance of HVAC electrical power and control  systems

1. Determine problerm in air-conditioning electrical system
2. Measure voltage in electrical circuit
3. Measure amperage in electrical circuit
4. Measure resistance in electrical circuit
5. Test electrical circuit for continuity
6. Test equipment for ground
7. Measure capacitance of capacitor
8. Make electrical connection
9. Analyze electronic circuit containing power source control card, sensor, and control device
10. Connect single-phase motor
11. Reverse rotation of single-phase motor
12. Connect three-phase motor
13. Determine circuit breaker and wiring sizes
14. Install equipment service panel
15. Install circuit breaker in service panel
16. Install electrical conduit
17. Install wiring in conduit
18. Install Romex cable
19. Install low-voltage cable
20. Connect electrical power to equipment
21. Connect electric duct heater
22. Connect humidifier
23. Install room thermostat or humidistat
24. Install outdoor, duct-mounted, or equipment-mounted thermostat
25. Install transformer
26. Install heat/smoke detector
27. Install hard-start kit on hermetic compressor
28. Install magnetic coil in motor starter
29. Install mtoro contactor
30. Install relay
31. Install heat-pump defrost timer
32. Install defrost thermostat
33. Connect pressure switch
34. Install antishort-cycle time
35. Conect electronic filter
36. Install control switch (fan, temperature-limit, or fan and limit combination)
37. Connect gas valve
38. Install pilot safety switch
39. Install glow-coil assembly
40. Install door switch (panel switch)
41. Install thermocouple or thermopile
42. Install stack-switch safety control
43. Install flame-sensing electronic sensing device
44. Install spark-ignition pilot lighter
45. Install direct-spark igniter system
46. Troubleshoot spark-ignition control system
47. Install primary control unit
48. Check manufacturer’s wiring on equipment
49. Replace starting or run capacitor
50. Replace potential relay
51. Install positive temperature coefficient (PTC) start device on a PSC motor
52. Replace motor overload protector
53. Replace electric-heater element
54. Replace electrostatic filter element
55. Replace solid-state control board
56. Replace solenoid coil
57. Install crankcase heater
58. Install oil-line heat tape
59. Replace electric-heater sequencer

58 Procedural Guides – Measuring, adjusting and troubleshooting HVAC systems:

1. Measure temperature in air-conditioning system
2. Measure refrigerant temperature
3. Locate leak in charged refrigerant circuit using electronic leak detector
4. Locate leak in uncharged refrigerant circuit using nitrogen pressurization
5. Locate leak in charged refrigerant circuit using halide leak detector
6. Test refrigeration system using refrigeration manifold gage set (A/C and heat pump)
7. Transfer refrigerant from storage bottle to charging cylinder
8. Evacuate refrigeration circuit (new or contaminated system)
9. Charge air-conditioning system with gas in low side .
10. Charge air-conditioning system with liquid in high side
11. Repair leak in refrigerant circuit
12. Add oil to compressor
13. Check refrigerant using electronic sight glass
14. Start equipment
15. Check system operating conditions
16. Check heat-pump cycles (changeover and defrost)
17. Adjust pressure switch on operating refrigeration system
18. Adjust temperature switch
19. Adjust defrost cycle on heat pump
20. Adjust refrigerant superheat
21. Adjust hot-gas bypass
22. Calibrate thermostat
23. Calibrate humidistat
24. Measure CFM air flow in duct
25. Measure pressure drop across coil or filter using manometer and probes
26. Measure air flow at register
27. Measure relative humidity
28. Adjust fan speed for correct CFM output
29. Balance duct system for correct CFM at each register
30. Adjust fresh-air intake
31. Adjust bypass damper
32. Adjust relief damper
33. Check static pressure at fan discharge
34. Set V-belt tension
35. Align belt sheaves
36. Check motor current (amps)
37. Check motor speed on multispeed motor
38. Test phase balance on three-phase motor
39. Adjust compressor start-delay timer
40. Adjust compressor unloader
41. Lubricate bearings
42. Adjust gas pressure
43. Purge air from gas line
44. Adjust burner primary air on oil furnace
45. Adjust burner air on gas furnace
46. Adjust pilot flame
47. Adjust pilot igniter
48. Adjust direct spark igniter
49. Determine furnace efficiency through combustion
50. Test for gas leaks
51. Adjust burner oil system
52. Adjust furnace draft
53. Test flame-proving and safety control
54. Fill water-cooled condenser and cooling tower
55. Adjust condenser water-flow controls
56. Explain system operation to user
57. Explain maintenance requirement to user
58. Clean work site and make final inspection after job completion

44 Procedural Guides – Measuring, adjusting and troubleshooting HVAC systems:

1. Determine needed system maintenance and repairs
2. Install pressure switch (high, low, and oil)
3. Clean coils
4. Clean humidifier
5. Clean fan
6. Straighten coil fins
7. Clean register
8. Replace fan bearing
9. Replace V-belt
10. Replace V-belt sheave
11. Clean electrostatic filter element
12. Test hermetic compressor
13. Check refrigerant charge
14. Attempt to start stuck hermetic (single-phase) compressor
15. Test compressor oil for acid
16. Replace hermetic compressor without service valves
17. Replace compressor with service valves
18. Replace fan motor
19. Replace fan blade
20. Replace fan wheel (cage fan)
21. Replace motor mount
22. Replace evaporator coil
23. Replace condenser or outdoor coil
24. Replace gas regulator
25. Replace gas orifice
26. Replace gas burner
27. Replace gas heat exchanger
28. Replace gas safety valve
29. Replace gas valve
30. Replace pilot burner
31. Replace oil burner (chassis and air tube)
32. Replace burner nozzle
33. Replace oil-burner motor
34. Replace fuel oil pump
35. Replace primary fan
36. Replace fuel cutoff valve
37. Replace fuel-filter cartridge
38. Acid clean condenser water circuit
39. Treat cooling-tower water
40. Replace water-pump seal
41. Replace cooling-tower water-level control valve
42. Clean system after burnout
43. Clean furnace and components
44. Replace ignition electrodes