HVAC What You Think You Know Vs

Home , Grease duct

RFMA 2021 Charlotte June 22 ‐ 24, 2021

HVAC What You Think You Know vs. What You Need to Know

Part 1 Knowing the HVAC Systems

Type 1 and Type 2 Systems

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Typical Restaurant Design Review

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New Tech Restaurant Design Review

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Preventative Maintenance Program

Why Bother with Preventative Maintenance?

 Refrigeration equipment will operate more efficiently and fewer hours per day. This translates into reduced electrical consumption…saving money

 Extends the operating life of your equipment; therefore, delaying the substantial cost of equipment replacement

 Reduces emergency service repair costs by resolving many potential problems prior to failure

 Lowers equipment failure rate…Frequent equipment failure can hinder the success of your business

 Savings in electrical consumption + reduced repair cost should more than offset the cost of implementing a refrigeration PM program

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Currently the average delivered efficiency from package heating, ventilation, air conditioning (HVAC) units in the US averages less that 60% of their rated capacity. Learn how the delivered efficiency can be improved to over 90%.

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A New Recipe for HVAC System Performance & Efficiency

• Restaurants consistently have the highest energy costs per square of any commercial building type. • How efficient are most HVAC units operating today? • Review the most common mechanical and airflow issues that have been found while auditing more than 300 HVAC systems. • Review a recent case study showing significant improvements in operating efficiency, lowered energy costs and increased comfort for customers and employees. • Review how mechanical cooling efficiency can be effectively measured, diagnosed and improved using new technologies proven in recent studies. • Airflow, electricity, pressures and temperatures are invisible. By understanding how these elements can be controlled and managed, you can gain control of these unseen costs in your buildings and make them visible. • Learn why California and electrical utility representatives are becoming more focused helping rate payers find solutions and incentives to help customers reduce kW and improve operating efficiency of HVAC equipment. • Learn how the collaboration among an electrical utilities, HVAC contractor and a restaurateur resulted in significant operating savings and financial incentives. • Learn the financial benefits of improving the operating efficiency of HVAC equipment. • Learn of possible solutions to reducing your operating costs and increase your bottom line.

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Energy Intensity by Business Type & Size

• Restaurants are among the highest consumers of electricity per square foot of all business types. The whole business average Energy Intensity for CSS businesses is 10.2 kWh/Sqft.

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ASHRAE/ACCA 180 Quality Maintenance Standard

CONTROL PANEL CONDENSER FAN/MOTOR • Sequence & test all •Perform vibration test controls •Lubricate bearings • Calibrate and clean controllers •Examine motor mount resiliency and safety controls •Check motor insulation resistance •Check thermostat daily & temperature time schedules CONDENSER COIL •Check set‐point of controls •Clean finned surfaces • and limits GAS BURNER SECTION •Perform combustion and draft ELECTRICAL tests DISCONNECT •Inspect and clean nozzles •Inspect •Inspect, clean and lube burner fan contacts (gun type burners) •loose •Test safety controls connections •Check for proper RETURN AIR FAN/MOTOR & operation SUPPLY FAN/MOTOR FILTER SECTION •Perform vibration test • Replace •Lubricate more bearings •Check motor insulation resistance disposable filter •Examine motor mount resiliency. media as required REFRIGERANT AND REFRIGERATION COOLING COIL COMPRESSOR •Lubricate bearings and check for • Inspect and clean as required end play, excessive bearing temp FRESH AIR, ECONOMIZER, RETURN, •Check crankcase heater operations • Check condition of finned surfaces and wear •refrigerant charge and oil level and AND EXHAUST AIR and straighten if bent •Check blower and clean dirt DAMPERS condition • Check for corrosion and leaks accumulation •Check for unrestricted and proper •Perform refrigeration performance •Check condition of drive couplings operation and close‐off evaluation and belts •Check Economizer motor & controls •Observe bearing and operating •Check for alignment, balance, •Lubricate bearings as required surface temps security to shaft •Measure vibration •Check rotation

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Common System Issues

Inefficient supply fan

Inefficient refrigeration circuit

Improper economizer operation

Inefficient heat transfer

Leaking cabinet and ductwork

Incorrect thermostat/EMS settings

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Coils

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Plugged Coil

Cottonwood Season

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Coils – Fin combs and Jacks

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Typical HVAC Air Distribution Faults

Excessive filter Inadequate fan airflow restriction Excessive economizer Roof curb leakage and airflow bypass

Undersized or poorly Excessive duct losses installed and restrictive through air leakage and duct systems inadequate insulation

Improper register airflow

Each airflow defect can be measured, diagnosed and repaired

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Typical HVAC Refrigeration Faults

Dirty and plugged condensing coil Dirty and plugged evaporator coil Inadequate equipment airflow Improperly charged refrigerant circuit

Damaged and leaking Damaged Compressor coil Contaminants in refrigerant

Each refrigerant defect can be measured, diagnosed and repaired

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Identify & The Resolve Hidden Faults

Refrigerant flow Invalid ACCEPTABLE: Safe restriction. data Pre-test Diagnoses and reasonable Number % Each 5% 5% performance. 10% Tests Diagnosis Pre‐test Diagnosis Reduce evaporator ACCEPTABLE: Safe and airflow. 35 10% reasonable performance. 4% 100 30% Add charge. Low-side heat transfer problem. 40 12% Recover charge. 16% Add charge. 4 1% Adjust TxV valve. 30% 57 17% High‐side heat transfer problem. High-side heat 55 16% Low‐side heat transfer problem. transfer problem. 17% 14 4% Reduce evaporator airflow. Recover charge. 17 5% Refrigerant flow restriction. 12% 15 4% Invalid data 337 Total Pre tests Post‐test Diagnosis Adjust TxV valve. ACCEPTABLE: Safe and 1% 311 100% reasonable performance. 311 Total post tests Less than 10% of the Refrigeration Circuits met the baseline performance requirements for the SCE Standard 180 program

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Typical HVAC Electro-Mechanical Faults

Economizer Sensors inoperable Refrigerant circuit controls failing

Economizer linkage and Electrical components drive damaged or not and control have failed adjusted

Occupants reprogram thermostats and control Control system become systems nonfunctional or fall out of calibration

Each mechanical and control defect can be measured, diagnosed and repaired

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Typical Performance Repairs

• Reduce filter resistance to airflow

Filter restriction decreased Restrictive filter 400 CFM per ton 260 CFM per ton

Increasing filter surface area or using less restrictive filters will increase airflow and operating system efficiency

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Typical Performance Repairs

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Typical Performance Repairs

• Improve duct installation

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HVAC Airflow Definitions

Supply Air – Air Delivered to the space from an HVAC unit like a Rooftop, DOAS (Dedicated Outdoor Air System), Split System & MUA (Make-Up Air Unit).

Return Air – Air returned to the HVAC unit from the space.

Outdoor Air – Air brought in from outside from the HVAC system(s) like a Rooftop, DOAS, MUA, etc.

Mixed Air – Return & Outdoor Air air mixed prior to being heated, cooled or dehumidified in an HVAC unit.

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HVAC Airflow Definitions

Exhaust Air – Restaurant exhaust air path like Kitchen Hoods, Dishwashers, Restrooms, HVAC unit exhaust (Barometric Relief or Power Exhaust).

Make-Up Air – Conditioned or tempered outdoor air introduced into the Kitchen to replace hood exhaust.

Transfer Air – Air transferred from one zone to another to balance and make up for exhaust – air transferred from the Dining  Kitchen.

Replacement Air – All air paths that make up or replace the restaurant Kitchen exhaust.

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HVAC Airflow Definitions

C & C– Capture & Containment of heat gain and effluent by the Kitchen hood systems. End panels and increased hood overhang are often incorporated to facilitate better C & C.

Perforated Diffuser– Diffuser style recommended for supply and make-up air around the hood systems. Low velocity with no pattern to create a column of air directed toward the floor as to not disrupt C & C.

Perforated Supply Plenum (PSP) - Replacement Air – Linear style perforated supply and make-up air diffuser in front of the hood system. Two positions are typically applied: MUA position – tempered or conditioned MUA nearest the Kitchen hood. AC Position – stands off the hood where traditional perforated supply diffusers are located.

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The Refrigeration System

Compressor The heart of the system; the compressor circulates coolant (refrigerant) through two heat exchangers (condenser and evaporator) Condenser A heat exchanger similar to the radiator in your car. It removes the heat in the refrigerant vapor absorbed in the evaporator and condenses it from a vapor to a liquid Metering device Regulates the flow of refrigerant into the evaporator. It also creates a large drop in pressure causing the refrigerant to change from a liquid to a saturated liquid-vapor mixture Evaporator Absorbs the heat from the air and the product within the refrigerated enclosure. As the refrigerant turns to 100 % vapor, it returns to the compressor, starting the whole process over again

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Three Conditions of Refrigerants

Liquid Line Metering Device (Thermostatic Expansion Valve)

Condenser

Discharge Line Evaporator

Suction Line Compressor

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• What are these various gases cooling systems are running on?

• Why do they cost so much?

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Refrigerant Terms

• Chlorofluorocarbon (CFC) and Hydrochlorofluorocarbon (HCFC) are the original “Freon(R-12)” refrigerants. R-11, R-12, R-123 and R-502

• Hydrofluorocarbon (HFC) such as R-134a, R-143a, R-407a, R- 407c, R-404a and R-410a (a 50/50 blend of R-125/R-32) were promoted as replacements for CFCs and HCFCs in the 1990s and 2000s

Why do they cost so much?

As of 2020 HFCs (including R-404a, R-134a and R-410a) are being superseded with:

Residential air-conditioning systems using R-32 or R-600 (isobutane);

Car air-conditioning systems using R-1234yf;

Chillers for commercial refrigeration; air conditioning using R-1234ze Commercial refrigeration using CO2 (R-744).

• CO2 was used as a refrigerant prior to the discovery of CFCs (this was also the case for propane)[1] and now having a renaissance due to it being non- ozone depleting, non-toxic, non-flammable with a low Global warming potential of 1. • CO2 may become the working fluid of choice to replace current HFCs in cars, supermarkets, and heat pumps.

• Coca-Cola has fielded CO2-based beverage coolers and the U.S. Army is

considering CO2 refrigeration.

Note: Due to the need to operate at pressures of up to 130 bars (1,900 psi;

13,000 kPa), CO2 systems require highly resistant components, however these have already been developed for mass production in many sectors.

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Types of HVAC systems

Heat Pumps vs Splits vs Water Chilled vs Ductless Mini Splits

a) What are the differences?

b) The pros and cons of each

Types of HVAC systems

Heat Pumps

Split systems divide each system into its own unit, so your heater and air conditioner are separate. Most QSR and Fast- Food Restaurants have Split systems

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Ductless Mini-splits are heating and cooling systems that allow you to control the temperatures in individual rooms or spaces. Mini-split systems have two main components -- an outdoor compressor/condenser and an indoor air-handling unit(s) (evaporator).

The main advantages of mini splits are their small size and flexibility for zoning or heating and cooling individual rooms. Since mini splits have no ducts, they avoid the energy losses associated with ductwork of central forced air systems. Duct losses can account for more than 30% of energy consumption for space conditioning

The primary disadvantage of mini splits is their cost. Some people may not like the appearance of the indoor part of the system. While less obtrusive than a window room air conditioner, they seldom have the built-in look of a central system. There must also be a place to drain condensate water near the outdoor unit.

Water Chilled Systems

How loops work?

What to look for in leases for requirements.

(ex: water temp, strainers, maintenance schedule by Landlord, etc..)

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An open loop system is one that uses groundwater from a conventional well as a heat source in the winter and a heat sink in the summer. The groundwater is pumped through your heat pump, and the heat from the water is either extracted (in winter) or rejected (in summer).

Geothermal systems are open loop systems

A Closed-loop system is designed to transfer heat through circulating water for air conditioning, heating, or process applications. In many HVAC applications, the closed-loop water is circulated through an air handler coil, which either cools or heats the incoming air. This is the most common water chiller system

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Know your building zones:

• Kitchen vs Customer areas • Thermostat locations • Open vs closed kitchens

Typical Restaurant Design Review

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The importance of proper Air Balancing

• Positive overall, slightly negative in kitchen • Seasonal issues

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Energy costs across the Country will continue to rise!

Superior Energy Efficiency is a Competitive Advantage

If you are not measuring…you are only guessing

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When a Kitchen Exhaust System is Out of Balance…

By understanding how these elements can be controlled and managed, you can gain control of these unseen costs in your buildings.

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The volume of airflow in a commercial kitchen exhaust system may be up to 20 times greater that the airflow in a dining room. However, it is: • Invisible • Extremely expensive • Usually out of control • Often uncomfortable • Affects the quality of food • Determines employee production

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It is important to properly schedule the equipment with all features, configurations and an air balance schedule

RESTAURANT AIR PATHS EXFILTRATION (POSITIVE PRESSURE)

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HVAC Schedule

It is important to properly schedule the equipment with all features, configurations, acceptable manufacturers, complete model numbers, electrical and weight data with contacts for technical support and pricing guidance

Consider the use of active dehumidification cycles (hot gas reheat), economizers with reference enthalpy controls but no economizers in hot/humid ASHRAE Zone 1.

Properly apply evaporative coolers a moisture and maintenance perspective.

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Comfort & Energy

Guest and employee comfort is critical and a key aspect of any good restaurant design. Temperature, humidity, dew point and moisture management are on the minds of restaurant designers. Non-conditioned make-up air and other antiquated design philosophies can reduce comfort, increase humidity and result in moisture damage and bacterial growth. A properly designed system utilizing conditioned air can increase comfort and save in overall operating energy and decrease the total lifecycle cost or total cost of ownership.

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Space Operating Conditions

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• Know your climate zones

• One suit does not fit all areas.

• (Particularly in California where 30 miles near the coast can make a large difference on settings and layout )

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Economizers

FUN FACT

CHICAGO REGULATIONS ON ECONOMIZERS AND RESTAURANTRS ODOR CONTROL

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Findings Summary From Peter Jacobson’s Study for the California Energy Commission of 215 Commercial RTUs under 120,000 BTUs (10 tons)

Economizers

Refrigerant charge

Low air flow

Cycling fans during occupied period

Fans run during unoccupied period

Ducts outside conditioned space

Simultaneous heating and cooling

No outside air intake at unit

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Problem Frequency Note: Source “Small HVAC System Design Guide,” California Energy Commission, October 2003

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Performance Upgrades

• Economizer Upgrades & Retro Commissioning

Test, measure and verify economizer performance

Upgrade to the new generation of Advanced Digital Economizer Controls

Measure and adjust minimum and maximum airflow

Commission economizer

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Example of a recent advanced Economizer Control Upgrade KW Usage and Cooling Operation of a 20 Ton Roof Top Package Unit

% of Compressor Item KW Used Stage 2 KW

Economizer – Main Fan Only 3.0kW 14%

Economizer – Main and Exhaust Boost 4.5kW 20% Fan

Compressor Stage 1 14kW 64%

Compressor Stage 2 22kW 100%

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Kitchen Exhaust – Overview

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The Grease Exhaust System

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How a Kitchen Exhaust System Works

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Hood Filter Maintenance

Incorrect filter fit

• The hood and filters should be maintained on a regular basis. This should be evident no matter how long it has been since a professional service has cleaned the entire system. Filter must fit vertically to allow grease to drain

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Hood Filter Maintenance

Incorrect filter fit

Filter must fit vertically to allow grease to drain

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Hood Filters waiting for KEC

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Hood Filters Cleaned in Place

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Hood Filters Cleaned in Place

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Hood Filters Cleaned in Place

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Hidden Hood and Duct issues

Grease in the light globes are a sure sign of grease leakage above the hood

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Hidden Hood and Duct Issues

Grease in the light globes are a sure sign of grease leakage above the hood

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Hidden Hood and Duct issues

This access panel is neither grease tight nor a Listed assembly. This does not comply with NFPA 96, Section 7.4.3.3.

Grease in the light globes are a sure sign of grease leakage above the hood

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Hidden Hood and Duct Issues

EXAMPLES OF DUCTMATE F1 and F2 ACCESS: DO NOT USE THESE STYLE ACCESS PLATES ON GREASE DUCTS, THE GASKETS ON THESE DO NOT KEEP THE GREASE FROM LEAKING-USE THE UL LISTED DUCTMATE ULTIMATE PLATE ONLY

Grease in the light globes are a sure sign of grease leakage above the hood

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Hidden Hood and Duct Issues

Grease in the light globes are a sure sign of grease leakage above the hood

F2 door leaking already vs Ultimate door with zero grease leakage at 3 months in same concept with same sales figures.

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Hidden Hood and Duct Issues

Grease in the light globes are a sure sign of grease leakage above the hood

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Hidden Hood and Duct Issues

Ductmate Ultimate Access plate. UL listed for grease duct.

Grease in the light globes are a sure sign of grease leakage above the hood

Flamegard Access Plates. UL listed for grease duct.

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Hidden Hood and Duct Issues

Inside of Access Plate Latch Issue

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Hidden Hood and Duct Issues

You can see where the cleanings stop up the stack here 3 months after opening

Same concept after 15 years of the same neglect, they were getting cleaned quarterly!

Fans

• Types of fans • The differences between HVAC fans and exhaust fans • Cleanliness of fan blades • Proper rotation • Belted sets • Direct drive – Open vs Sealed motors, VFD’s etc.

Upblast Fan

Grease in the light globes are a sure sign of grease leakage above the hood

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Just When You Think You Have Seen Everything

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Inside an Exhaust Fan

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Inside an Exhaust Fan

• Broken Vibration Isolators

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Inside an Exhaust Fan

Motor air cooling intake

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Inside an Exhaust Fan Motor air cooling INTAKE SIDE Discharge side(back intakeOF FAN of fan blades) BLADES

Behind the fan blades are one of the most important areas of concern. Note: Intake side is clean, but the discharge side is not.

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