HVAC resource guide

diagnose. maintain. save.

Your tool to help you find efficiencies in your HVAC system, helping you save energy and money.

© 2013 W.W. Grainger, Inc. W-UCBD109

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ResoURCesdepartment of energy energy.gov

energystar® energystar.gov

united states environmental Protection Agency epa.gov

HVAc energy Management Products grainger.com/hvac

PRoDUCtscall 1-800-gRaingeR

Visit grainger.com® or download the grainger Mobile App at grainger.com/mobile

contact your grainger Representative

For more information, visit grainger.com/energy

Meter. Control. Save. Meter your HVAc system to help you develop an educated energy-efficiency strategy. Metering and submetering, long-established practices, help provide a snapshot of energy use and demand that you can use to help target savings opportunities. improved technology helps you to collect useful information from single or multiple devices and isolate the cause of excessive load spikes.

Reduce eneRgy use by 5 to 15%

meet sustAinAbility initiatives

eliminate oR shift energy sPikes to off-PeAk Hours

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Metering, when acted on, helps:

You Can’t Manage What You Can’t MeasureEnergy can be released as:• HeAt • electricity• steAM, Air and WAter Pressure• MecHAnicAl force

established as a best practice by energy stAr® in 1999*, energy logging helps provide a clear picture of when and where energy peaks occur. by using tools and services such as thermal imagers, meters and energy audits, you can gather data to help support the decisions of how to maintain or upgrade equipment and motivate others to change their behavior.

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$ Metered, ENERGY STAR-rated, buildings can generate an average of 20% annual savings.As reported in a 2009 occupant study completed for CBRE.

savings

Biggest Opportunities

Medium Opportunities

Smaller Long-Term Opportunities$

$ $$ $ $

According to a 2003 interview by William Feldman with Jean Lupinacci, director of the Commercial and Industrial Branch of Energy Star® at the EPA.

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$

$

$$$

$$

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$

HVAC, Motors & Drives

Lighting, Compressed Air, Steam Systems

Electric Utility, IT/Computers

Building Envelope

Power and energy Logger No. 1FBK3

energy Meter No. 12V820

*Source: Tudi Haasl, PECI, O&M Best Practice Series, Portable Dataloggers, 1999, energystar.gov

For more information, visit grainger.com/energy

Tune Up Your HVAC Equipmentr-22 refrigerant production will be phased out by 2020 and ozone depleting gas (Hcfc) production rates will decrease. With demand potentially exceeding allowable production levels, costs for r-22 refrigerant are likely to increase, making retrofit options more attractive.

before you decide to retrofit, test for leakage in your current equipment. if you have leaks or if your equipment breaks down, retrofitting your equipment now could help save you money in the long run.

if you require a retrofit, get a head start on choosing a suitable replacement at epa.gov

Proper Use of HVAC Diagnostic Toolstroubleshooting an HVAc system involves using sensitive diagnostic tools. With advancing technology, tools like leak detectors and digital manifolds can help pinpoint a problem. essentially, the proper instruments can help take the guesswork out of HVAc diagnostics.

With the right tools, you can also:• capture data efficiently• Assess and evaluate information over time• recognize variances in performance• isolate the cause of a problem • gather the necessary information to build a

case to take action in your facility

Source: Thomas Westerkamp, Diagnosing HVAC Problems, 2007, facilitiesnet.com

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Common Uses for R-22

• Use wireless multi-sensors Wiring can be expensive and may cause overheating or overcooling.

• Add automated diagnostics Provides real-time information and helps pinpoint a problem before it’s out of control.

• Replace or tighten loose control linkages Help prevent dampers from getting stuck open or shut.

• Install excess air controllers Adjust air volume to the burner to help increase boiler efficiency.

• Monitor boiler makeup water changes can indicate a leak in a boiler tube or condensate return systems.

Diagnostic and Monitoring Tools Can Help Reduce Energy Usage in your HVAC SystemRESIDENTIAL USES COMMERCIAL AND INDUSTRIAL USES

• Window air conditioning units

• dehumidifiers

• central air conditioners

• Air-to-air heat pumps

• ground-source heat pumps

• ductless air conditioners

• chest or upright freezers

• Packaged air conditioners and heat pumps

• chillers

• retail food refrigeration

• cold storage warehouse

• industrial process refrigeration

• transport refrigeration

it’s important to note that the phase out of r-22 is not a “use” ban. r-22 equipment may still be used and serviced after 2020 with existing inventory.

R-22 Refrigerant No. 2W198

Manifold Gauge & Hose set No. 12H947

Refrigerant Leak Detection Kit No. 2DPH7

For more information, visit grainger.com/energy

Reduce the Load on Your HVAC Systemreducing your facility’s HVAc load can help existing systems operate less frequently and allow newer systems to be more efficient. Here are some common load reduction strategies to help lower operating costs:

Sources: energy.gov, energystar.gov

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Get the Most from Your MaintenanceMaintain your equipment to help prevent mechanical breakdown and unplanned expenses. Annual pre-season check-ups are an easy way to help ensure your HVAc system is prepped and functioning properly before extreme weather kicks in.

When performing typical maintenance1, you should:• check thermostat settings

• tighten electrical connections

• lubricate all moving parts

• inspect electrical connections, the evaporator and condenser coils on your heat pumps and A/c units

• check system controls

• replace air filters regularly

• inspect ductwork and piping for leakage or damaged insulation

• repair old valves and steam traps

Maintain V-Belt Drives2 for Best PerformanceFollow these three steps to help improve your motor’s energy efficiency and life:

1. Use Raw Edged Cogged Belts – raw edged cogged belts grip the sheave sidewalls better, helping to minimize slip.

2. Replace Worn Sheaves – sheaves with as little as 1/32" of wear may cause your belts to slip excessively.

3. Tension Belts Correctly – the proper tension is the lowest tension at which the belt(s) won’t slip or squeal under peak load.

Sources: 1 Maintenance Checklist, energystar.gov 2 Replace V-Belts with Notched or Synchoronous Belt Drives, Motor Tip Sheet 5, energy.gov

thermostat No. 4NE58

V-Belt No. 6A115

Pleated Filter No. 2W231

Dishing

“Dishing” of groove side-walls shortens belt life

Belt should ride like this

Low riding belts indicate worn grooves

Check door openings and window seals, and plug leaks with weather stripping and caulking

Perform regularly scheduled maintenance• inspect ducts• inspect and replace belts• replace air filters

Evaluate motor and drive performance to help optimize productivity• consider variable frequency drives on air handling units,

cooling tower fans and chilled water pumps• install heat exchangers

Inspect and repair leaking or sticking steam traps

In dry climates, consider an evaporative cooler

Choose simple, integrated controls to help balance temperature and humidity

Insulate steam pipes

Review meter and submeter data

Pinpoint peak times and areas for energy usage

Consider air curtains for use on docks and in vestibules to keep heated or cooled air in and pests out

tighten up youR building envelope

contRol the humidity in youR facility

identify oppoRtunities foR savings

For more information, visit grainger.com/energy

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Steam Traps: Impact and Protectregular inspection and testing of steam traps helps protect your HVAc system. scheduled maintenance can help you avoid potentially dangerous conditions that can damage your HVAc equipment, pressurize the condensate piping or create a loss of energy.

Typically, there are four ways to test steam traps:

Determine if your steam traps are functioning properly.• establishing a routine schedule for inspection, testing and repair• documenting and reporting findings to help identify potential energy and cost savings• considering online or electronic monitoring of steam traps

Sealing the Building Envelopethe “building envelope” refers to all the components that make up the covering or skin of a building. this includes everything from the roof, every wall joint, window frame and door seal. A building envelope in poor condition can cause an HVAc system to become overworked and inefficient.

seals and tape are easy ways to fix known leaks. With the help of properly installed air curtains, you can also help minimize the loss of heat or cooled air through open doorways such as loading docks or walk-in coolers. see how air curtains can help you save energy and money by visiting:

Mars® Air curtains - marsair.com/content/roi-savings-calculator

berner® Air curtains - berner.com/sales/energy.php5

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teMPerAture

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sound

3.

VisuAl

4.

electronic

replacing failed steam traps typically provides a quick and easy return on investment. to schedule a steam trap audit, contact your grainger rep. steam trap audits are provided by a third-party affiliate of W.W. grainger, inc.

Source: Department of Energy, Inspect and Repair Steam Traps, 2012, manufacturing.energy.gov *Source: Leon Wang, AMCA International, Investigation of the Impact of Building Entrance Air Curtain on Whole Building Energy Use, 2011, amca.org

steam trap No. 4NU59

commonly used for warehouse and dock entrances, air curtains help save energy by helping prevent conditioned air from escaping and reducing the strain on your HVAc system. they also help protect open doorways from dust, fumes and pests while allowing customers and employees to enter quickly. Air curtains can pay for themselves within two years in energy-saving applications.*

For more information, visit grainger.com/energy

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Advantages of Variable Frequency Drives (VFD)1 A Vfd adjusts a motor’s output for peak demand and low demand so you get the most out of your motor while saving energy. A Vfd helps lower energy consumption, co2 emissions and mechanical stress with variable frequency drives.

With higher efficiency and improved performance, a Vfd helps offer reliable output, requires low maintenance and improves energy savings up to 70%2. A Vfd is ideal for applications where speed control is critical, such as when operating compressors, pumps and fans.

Other advantages include:• constant pressure, fewer pressure surges• increased service life• less mechanical stress• More precise control of the system• reduced noise levels• improved air quality

Addressing the Energy Dilemma energy demand and cost is on the rise. As federal and international regulations continue to develop to help reduce our global carbon footprint, a viable solution is critical for businesses and facilities to remain productive.

by addressing motors that control pumps and HVAc systems first, you can help address the energy dilemma and increase your productivity.

Sources: 1James Piper, The Benefits of VFDs in HVAC Systems, 2009, facilities.net 2Mark Gmitro, Pump Energy Savings with VFDs, 2009, sustainableplant.com

Source: energy.gov

30%of the energy of a building

60%of the

energy of an industry and infrastructure

85%of electric motors help

control pumps, fans and compressors

Motors can consume:

the energy dilemma

the facts the need

x2 ÷2vs.energy demand by 2050 CO2 emissions to avoid

dramatic climate changes

energy management is one of the keys to addressing the dilemma

Source: IEA 2007 Source: IPCC 2007, figure (vs. 1990 level)

AC Drive No. 6DWY7

VFD

VFD

Supply air

Boiler

Cooling Tower

Chiller

Return air

= Pump

= Fan

Air Conditioning & Ventilation

Water Cooling& Heating

VFD

VFD

VFD

VFD

Source: Zachary Shahan, Electric Motors Use 45% of Global Electricity, 2011, cleantechnica.com