Air Cooling Maintenance?

The time has finally come, and spring is here! The Cincinnati Reds are playing, Spring Soccer is happening early on Saturday mornings, and the FC Cincinnati Stadium is bustling here in Cincy. With that, temperatures are climbing, the grass and weeds are growing, and more and more families are out walking around and doing outdoor activities. With this, also comes warmer temps, and lots of spring allergies in the Farno household. As a dad, I have stepped into my role pretty well by trying to delay turning on the air conditioner until everyone else in the house is plotting my demise. This year, I achieved it by putting off the routine maintenance of the condensing coils.

In case you weren’t aware, here in the Midwest, where pollen runs rampant and the winds have been strong this year, it is a great idea to clean out the condensing coils on your home’s A/C system before turning it on for the year. Unfortunately, your home A/C system is not maintenance-free like the Cabinet Cooler Systems EXAIR offers; at the same time, your home needs a lot more than a few thousand BTU/hr of cooling capacity. When we first bought the home, I didn’t know this was a thing, as the home I grew up in didn’t have central air. We rocked Window A/Cs, and my parents still do. So, cleaning the outdoor unit was not part of my knowledge base. This is something I learned once the air conditioner wasn’t working, and I started to troubleshoot.

The main purpose of the condensing coils is to strip all the heat out of the refrigerant and get it to “condense” back into its liquid state to be pushed back through the orifice and continue to cool the air that is being passed over the A Coils inside the house. These coils are covered in fins that are very tightly spaced. The outside unit has a large fan that pulls the surrounding air in through the coils and exhausts the hot air up out of the top. There is no filter on that incoming ambient air, though, so all the leaves, cobwebs, pet hair, pollen, dirt, mulch, you name it, get pulled up into these fins. Over time, this starts to get a buildup, and the cooling fins will start to lose their efficiency. The fan won’t be able to pull as much air through, and eventually, the gas doesn’t get condensed, which then reduces the cooling and can cause other bigger issues. This is just like a refrigerant-based A/C panel cooler in a facility. Most of the time, they have at least a small filter on the air intake to try and reduce the contamination of the condensing coils. So I clean the A/C condenser at my house using a coil cleaning solution diluted down, a pump sprayer, and a regular garden hose.

The main thing to remember when cleaning this is that the majority of the dirt is from the air being pulled into the center by the fan. So I rinse the coils from the inside out and make sure I have free passage all the way through. The water doesn’t need to be a high-pressure rinse like an OmniStream nozzle or one of BETE’s NF Nozzles, just a simple low-pressure stream of water to get between the fins and push all contaminants as well as rinse the solution away. Remove any leaves or other unwanted debris from inside the unit and then bolt the fan and cage back down. Then let the family enjoy some cold air inside the house.

This type of maintenance is something that easily gets overlooked when looking at refrigerant-based electrical panel coolers. That is where EXAIR Cabinet Cooler Systems shine. The only filter you have to worry about is a redundant point-of-use compressed air filter that is included with the Cabinet Cooler Systems. No chemicals needed for cleaning, no water, no mess to change out a compressed air filter, just long-lasting performance. If you want to talk about how to change your control panels over to Cabinet Cooler Systems, contact an Application Engineer today.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Father’s Day Weekend & Leak Detection

In case you didn’t know, yesterday was Father’s Day. In our household, both Father’s Day and Mother’s Day are pretty low-key, and we normally just get some much-needed family time in. This year for Mother’s Day we prepared the patio and outdoor living space at our home for the Summer activities. For Father’s Day, the schedule was a little different. My wife and oldest had a play to go to in the early afternoon and I had a list of repairs to do as well as some recovery from a dodge ball tournament on Saturday. While most of my repairs were things like fixing a leaking hose, unpacking from the tournament, and weeding the garden, I did not have any major repairs on my list which meant I could take the younger two daughters and head to the pool. That ice-cold water definitely helped with the recovery part of my day, so we went. Met the rest of the crew after their show and had some nice ice cream time then home. I was feeling pretty good as my tasks were all completed, and I was going to be able to just enjoy the meal my wife had fixed for dinner and play some games with my girls. Well, the house had other plans, we arrived home to a thermostat that had crept up while we were gone.

Ice from the compressor line in the condensing coil.
While the leak detector wasn’t out, there was no shortage of thermometers being used here along with a slide rule. (Leak Detection had been completed.)

Now, our HVAC system has limped along for probably a decade longer than most, and we continue to regularly maintain it. This is a true testament to how well preventative maintenance can truly expand the life of an item. Needless to say, during my routine inspection and maintenance at the start of the year, we found the unit was low on refrigerant. One of the first steps we performed when we saw it was starting to freeze up was to begin testing for leaks. This task takes a special gas detection meter that will sniff out the refrigerant vs. just air movement. Sure enough, we found a corroded joint in the A-Coil that has developed a fairly considerable leak. This tool made me think of the Ultrasonic Leak Detector that we sell here at EXAIR. It also made me start to correlate how a leak in a refrigeration system can cause the entire process to ice over because there isn’t enough refrigerant present and so the entire system begins to work harder and harder and the coil temp drops below freezing. The humidity in the air begins to collect on the A-Coil inside the house because the coil is so much cooler than the humid air around it and the ice starts to form. Once the ice forms you restrict the airflow through the coil which causes more ice to form and eventually no airflow happens and the entire compressor line will freeze. This often can lead to other failed parts if not discovered early enough. How is this like a compressed air system?

Well, leaks in a compressed air system cause the compressor to work overtime. It drops efficiency within the other items in the system which creates a lack of performance and potentially shuts down the system. Leaks can be found by utilizing a less specialized, Ultrasonic Leak Detector which can be seen in operation in the video below. Fixing these leaks can easily put capacity back in and save additional maintenance and replacement costs.

If you want to discuss how the Ultrasonic Leak Detector can save you money and costly shutdowns, contact an application engineer today.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

What Is A Btu?

A Btu, or British Thermal Unit, is a traditional unit of energy and is a measure of the heat content of fuels.

Originally, the Btu was the amount of energy needed to increase the temperature of 1 pound of liquid water by 1 degree Fahrenheit.  The term became common among engineers in the late 1800’s.

A single Btu is insignificant in terms of the amount of energy used by a single household or by an entire country. In 2013, the United States used about 98 quadrillion (written out, 1 quadrillion is a 1 followed by 15 zeros) Btu of energy.

One Btu is approximately equal to the energy released by burning a match.

Match

Interesting Energy Conversion Factors

Energy source Physical units and Btu (averages,¹ 2012)
Electricity 1 kilowatt hour = 3,412 Btu
Natural gas 1 cubic foot = 1,025 Btu
Motor gasoline (10% ethanol) 1 gallon = 120,524 Btu
Diesel fuel 1 gallon = 138,690 Btu
Heating oil 1 gallon = 138,690 Btu
Propane 1 gallon = 91,333 Btu
Wood 1 cord = 20,000,000 Btu (Estimated)

1Weighted averages across different contexts of each fuel such as imports, exports, production, and consumption. Source:  www.eia.gov/EnergyExplained by the U.S . Energy Information Administration

EXAIR manufactures the Cabinet Cooler System.  The Cabinet Cooler System is a low cost, reliable way to cool and purge electronic control panels.  They incorporate a vortex tube to produce cold air from compressed air – with no moving parts! EXAIR Cabinet Cooler Systems are available for NEMA 12, 4, and 4X type enclosures.  For the most efficient way to operate Cabinet cooler, a thermostat control system would be utilized. The standard thermostat control systems include an adjustable thermostat factory set at 95F.  Also, available is the ETC Electronic Temperature Control, providing precise control with easy adjustability and a digital readout.

Cabinet Cooler Family
EXAIR Cabinet Cooler Systems

In the United States, the power of HVAC (Heating Ventilating and Air Conditioning) systems is often expressed in BTU/hr.

The EXAIR Cabinet Cooler Systems are available with cooling capacities ranging from 275 to 5,600 Btu/hr.  To cool the down the equivalent of 98 quadrillion Btu’s of energy used by the US in 2013, it would take 17.5 trillion of our largest Cabinet Cooler Systems!

If you would like to find out how many Btu’s of cooling your electrical cabinet needs, please fill out and send in the Cabinet Cooler Sizing Guide and we can let you know.

Brian Bergmann
Application Engineer
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Match Photo courtesy of Samuel M. Livingston via Creative Commons License