Equipment Maintenance: Impact on Efficiency. Matt Killen, LACAP, Baton Rouge, LA
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1 Equipment Maintenance: Impact on Efficiency Matt Killen, LACAP, Baton Rouge, LA
2 All equipment should be maintained and or calibrated to ensure accuracy and eliminate down time. Trucks, Generators, Power Tools and Insulation Machines need to be maintained according to Manufacturers instructions. Regular maintenance is required for efficiency and long life of equipment.
3 CO Analyzer s and Manometer s require regular maintenance and calibration. CO Analyzer s require calibration every 6 months. Manometer s (DG-700 & DM-2) require calibration once per year.
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6 Regular maintenance will help to avoid costly repairs! In order to guarantee a successful program, equipment maintenance must be one of the essential components. A proper maintenance program starts with ensuring that one person is designated and responsible for the maintenance.
7 Benefits of Preventative Maintenance Preventative Maintenance increases the efficiency and speed of your equipment. Reduce the cost when the work done is faster and the machine doesn't break down in the middle of the work. Save money since preventative maintenance would cost less than repairs and replacement.
8 Benefits of Preventative Maintenance Ensures the safety of the person who is working with the machine!!!
9 This can be accomplished with Maintenance and Calibration log books or computerized software programs. There are many software programs that can help you set up a routine schedule. Maintenance Software Programs should be easy to learn and understand. The software should be quick and easy to use.
10 Sample Forms
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16 Fill out form and send with equipment. Used for both calibration or repair.
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18 The DG-700 has a sticker on the back that indicates the date of calibration. The Energy Conservatory recommends the DG-700 be recalibrated once every year. The Gauge should be sent to: The Energy Conservatory st Ave. S, Suite 160 Minneapolis, MN Attn: Digital Gauge Recalibration
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22 Some routine maintenance for the DG-700 includes checking the batteries and replacing as needed. Whenever the gauge is turned on, the battery voltage is measured and temporarily displayed on channel B.
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24 If the gauge locks up or displays inconsistent readings try turning the gauge off for 5 seconds and restarting. If this fails then remove the batteries and hold down the on/off button for 5 seconds to discharge the gauge s internal electronic components.
25 Blower Door Fans Blower Door Fans maintain their calibration unless physical damage occurs. Some things to check for are: Damaged Blower Door Fan Sensor and Blower Door Motor Position.
26 Blower Door Fans The flow sensor is the white ring which is permanently attached to the end of the motor opposite the fan blade. It is perhaps the most critical part of your blower door fan.
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28 Blower Door Fans Procedure to check for damaged blower door fan sensor: Visually inspect to confirm the sensor is not broken or deformed due to impact. Check that the clips which hold the sensor in place are properly engaged.
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30 Blower Door Fans Next perform a test for sensor leakage: Attach the fan pressure tubing to the tap on the blower door fan.
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32 Blower Door Fans There are four intentional holes in the flow sensor. Temporarily cover these with masking tape.
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35 Blower Door Fans Create a vacuum in the fan pressure tubing by sucking on the open end of the tubing. Make sure the pressure persists for at least 5 seconds. If you can t maintain the vacuum then the sensors leak and need replaced.
36 Blower Door Fans If a fan has been dropped, the motor may have shifted from it s proper position. This can degrade fan calibration. Lay the fan on it s side with the flow sensor facing up. Place a straightedge across the inlet of the fan.
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38 Blower Door Fans Use a ruler to measure the distance from the bottom of the straightedge to the face of the flow sensor. This distance should be 3/16 th to 5/16 th inches.
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40 Blower Door Fans Examine motor cooling holes for excessive dust. Clean as needed. Inspect housing, blades and guards. Clearance of blade tips relative to the fan housing should be about ½ of clearance.
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42 Combustion Analyzer Calibration and Maintenance Bacharach recommends their analyzers be calibrated once every 6 months. Equipment can be sent to Bacharach.
43 Combustion Analyzer Calibration and Maintenance There are other companies that offer this service. Some companies will come to you and service all your equipment on site.
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46 CO Analyzer s Before each use, inspect the filter element and replace as needed. When liquid is seen inside the water trap, empty the trap before it becomes full. Always check batteries and replace as needed.
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48 Gas Leak Detector Always check batteries and replace as needed. Periodically check the sensitivity by exposing the sensor to a source of gas. Routinely check the probe filter and replace if dirty. A dirty filter will shorten the life of the sensor.
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50 Insulation Machine Maintenance Tips Keep it clean. Keep material from accumulating on blower filter. After use empty hopper and blow out hose.
51 Insulation Machine Maintenance Tips Keep the chain lubricated. Use a dry film lubricant (DOW 321) Check sprockets for wear, replace as needed.
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56 Insulation Machine Maintenance Tips Periodically check oil level in speed reducer
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58 Insulation Machine Maintenance Daily: Empty fiber from machine Weekly: Clean blower filter and vacuum fiber and debris from under machine
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62 Insulation Machine Maintenance Monthly: Check airlock seals and plates for damage. Visually inspect and/or re-tighten all chains and sprockets.
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65 Insulation Machine Maintenance Quarterly: Grease all bearings with NLGI #2 Grease 4 main auger bearings, 2 airlock bearings and 4 shredder bearings. Replace blower filter if needed.
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69 Diesel Generator Maintenance The engine will need an oil change every 100 to 250 hours depending on the dust conditions. Change the oil filter every time you change the oil.
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72 Diesel Generator Maintenance Air filters need to be changed as required depending on how much dust is in the air. Check the air filter every 100 hours and every 50 hours in dusty environments.
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74 Diesel Generator Maintenance Fuel filters are normally changed every 200 to 250 hours depending on how clean the fuel and dust conditions. Use a fuel stabilizer on gas generators that will sit for extended periods of time.
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76 Always follow Manufacturers Instructions and Maintenance schedules.
77 Questions?
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