Last month, we discussed how many Air Upgrade projects fail during the handoff from sales to installation. This month, we’ll wrap up the Air Upgrade series with how to verify an Air Upgrade works as intended. We’ll also discuss how to handle situations where the results aren’t as planned and how you can correct those situations. Let’s look at this final and often overlooked step that’s critical to Air Upgrades fulfilling everyone’s expectations.
The Need for Verification
You would think that any company committing to the level of work we’ve discussed over the last five articles would want to know how well their Air Upgrades worked. Unfortunately, many have no idea because verification is one of the most skipped steps in the process.
It’s easy to assume that because you designed the upgrades based on solid design principles and industry standards that everything works as planned. Unfortunately, design alone is insufficient and often varies from the brutal realities of field conditions. Don’t be arrogant and assume your intended results will magically appear when you’ve completed the job. On the other hand, don’t be afraid to acknowledge test results that may be different than what you intended. You can’t improve what you don’t know.
Essential Test Instruments and Accessories
The verification process uses all the test instruments, skills, and apps you previously used to discover, diagnose, and sell the Air Upgrade. You’ll use this combination at the end of the project to see how well the repairs perform. Bring your best test instruments for this final step. They include:
- A Static Pressure Kit — to see changes in static pressure readings;
- Digital TrueFlow Grid — to confirm improvements in fan airflow;
- Airflow Hood (optional) — to show airflow improvements in individual rooms or areas; and
- Dry bulb thermometer (optional) — to gauge duct temperature loss and gain.
To maintain consistency between test results, it’s best to use the same instruments and follow the same test procedures. Mixing test instruments, procedures, and apps could create unnecessary confusion and inconclusive results. Keep things simple and repeatable so your customer can see the difference and understand what you’re showing them.
Testing the Air Upgrade
Now that you’ve assembled your gear, it’s time to test the Air Upgrade and compare actual test results to intended results. At this step, you will see how much difference your work made to the system. Be sure to bring the original test results and any reports with you.
Start by turning on the equipment and setting the thermostat to the same mode of operation you tested in at. If you did the original test in cooling mode, your test out should also be in cooling mode. Ensure the blower has reached full speed, and then measure:
- Total external static pressure (TESP);
- Filter pressure drop (∆p);
- Coil pressure drop (∆p); and
- Supply and return duct pressures.
If you perform the readings with the AirMaxx workflows in the measureQuick (mQ) or The Energy Conservatory (TEC) apps, they will guide you through the testing sequence and make the data collection process repeatable. If you gather the readings without one of these apps, measure TESP first, then pressure drop across the air filter and coil, and finish with duct pressures.
Compare your new pressure measurements against the original pressure measurements to see how much the readings improved. Next, compare the new measurements against NCI pressure budgets or manufacturer specifications. A successful Air Upgrade should have pressures less than 140% of design.
Next, measure fan airflow with a Digital TrueFlow Grid. Follow the steps in TEC’s TrueFlow app and compare the results with your test-in readings. Ideally, fan airflow should be within ± 10% of required fan airflow. If you are within this percentage and have acceptable static pressures, you’ve done a great job. However, sometimes, you may need to make a fan speed adjustment to get the proper fan airflow. If you change the fan speed setting, don’t forget to go back and measure static pressure again because the readings will change.
Depending on the scope of the Air Upgrade, this might conclude your airside verification testing. Don’t forget to make a final check of the refrigerant charge and adjust as needed. If you made duct modifications to individual rooms, you may also include additional measurements such as room pressures and grille and register airflow. Also, compare these measurements to your test-in values to ensure they fall within acceptable ranges.
Finishing this step can be either the most rewarding or most frightening part of an Air Upgrade. If your readings improved and are within acceptable ranges, congratulations! It’s time to share the outcome with your customer. But if your readings aren’t within range, then what?
When an Air Upgrade Misses the Mark
Sometimes you won’t get the results you expected. As Rob Falke used to say, “Bummer, dude.” How should you deal with this situation? If you practice on your own installs before going live with your customers, you’ll minimize these incidents. But unfortunately, they do happen. Thankfully, you can address any issues before they become full-blown problems.
Some of the greatest learning experiences come from finding what really works versus what you thought would work. Remember, design often varies due to unforeseen field conditions. These conditions can and will limit access to ducts and assembly of the materials. Do the best you can with the situation. If you have access to the ducts, find the static pressure readings that are farthest out of range and focus your attention on relieving excess pressure.
Next Steps
Before any of the steps in the Air Upgrade process work, you have to start. Don’t procrastinate or make excuses. Begin by getting the right gear. You can’t play the game unless you have test instruments and accessories. Remember, you can start out as small as a manometer and fan tables and then work your way up. I’ve gotten text messages from our Airflow Testing and Diagnostics class students telling me of their successes just days after completing the training.
Once you have the right gear, start testing and diagnosing your own installations. A great place to begin are problem jobs, office systems, or homes of employees who have comfort, efficiency, or equipment problems. Not only does this step help you hone your skills, it gives employees ownership of this new and unique product offering. They will brag about the results more than you think.
Also, teach others in the company. We learn best by doing and sharing those lessons. Start with the smallest steps you can think of as you document your journey. The biggest mistakes often make the best training subjects. Expect mistakes as you learn and use them to build an Air Upgrade culture in your company.