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ROOFTOP UNITS
Understanding RTUs, their operation,
preventive maintenance and current
technology can help keep your customers’
systems online and optimally operating.
[Editor’s Note: This feature has been left in first person to main-
tain the author’s personal experience.]
I
started to work on rooftop units (RTUs) more than 30 years
ago. As a young apprentice, I quickly learned several things
about working on these systems, including what a rooftop
unit is, how these systems operate, preventive maintenance
and current technology. This article will focus on exactly
these points. Knowing if the issue is on the cooling side or the heating
side (shown here) of an RTU helps eliminate many compo-
nents that are in need of troubleshooting.
Checklist Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Clean
Return
Air
Grilles
Replace
Return
Air
Filters
Replace
Unit
Disposable
Filters
Clean
Unit
Outside
Air
Filters
(Metal)
Check
Condensate
Drain
Inspect
Evaporator
Coil
Inspect
Condensor
Coil
Check
For
Noise
or
Vibration
Check
Supply
Air
Flow
cfm/Velcoity
Air
Side
CHECK
FAN
BELT
TENSION/
REPLACE
IF
NEEDED
EVAPORATOR
FAN
WHEEL
FOR
DIRT/CLEAN
IF
NEEDED
INSPECT
MOTORS,
STARTERS/CHECK
ELECTRICAL
CONNECTIONS
LUBRICATE
ALL
BEARINGS
IF
NEEDED
CHECK
ECONOMIZER
(DAMPER)
OPERATION
OUTSIDE
AIR
DAMPER
CLOSES
W/UNIT
DAMPER
OPEN
W/UNIT
ON
Gas
Heat
CHECK
CONDITION
OF
HEAT
EXCHANGERS
&
COMBUSTION
AIR
BLOWER
CHECK
FOR
PROPER
PILOT
IGNITION
CHECK
FOR
PROPER
BURNER
FLAME
APPEARANCE
CHECK
HEAT
EXCHANGE
LIMIT
SWITCH
CHECK
UNIT
HEATING
CONTROL
SEQUENCE
Cooling
CHECK
FOR
DIRTY
CONDENSER
COIL
CHECK
FOR
DIRTY
EVAPORATOR
COIL
CHECK
FOR
REFRIGERANT
PRESSURES/TEMPERATURES
CLEAN
CONDENSATE
PANS
AND
DRAINS
CHECK
CONDITIONED
AIR
DISCHARGE
TEMPERATURE
CHECK
UNIT
COOLING
CONTROL
SEQUENCE
This is a sample of a preventive-maintenance schedule for RTUs. Always take into consideration the make of the
system and manufacturer recommendations when creating a PM schedule for a customer.
pressure switch will not close and the system will not run. Look the building at a slight positive pressure. Some manufactures
for items such as a no call for heat, blocked exhaust, pressure will use dry-bulb or enthalpy sensors to automate this process.
switch is not being made or there is a bad air-pressure switch. It is important you find out which are being used.
If everything appears normal and all safety precautions have
been made, watch the unit as it fires up. Some units have a pilot Preventive maintenance
while others light off directly with no pilot. Is the unit using a Customers are always told that the unit will fail to func-
hot surface igniter or electrodes to light off the fuel. Thirty years tion, not work properly and waste energy if preventive
ago, most items were mechanical, but today most units are full of maintenance (PM) is not performed. Yet, year after year,
electronic boards and will flash a message or use lights to explain customers still neglect to perform preventive maintenance.
what is occurring. In these cases, it is very helpful to attend a It has been made worse by the economy because customers
manufacturer’s training seminar through the manufacturer or attempt to save money by not performing necessary (and
a local supply house. These seminars provide valuable short- sometimes costly) maintenance. It is up to skilled techni-
cuts and information that can be used out in the field. As cians to sell them on the benefits of preventive mainte-
RSES frequently states, education is truly power. nance. Rooftop units are no different than any other piece
It is important to look at the configuration of the return, of equipment. It is always best to follow the manufacturer’s
outside and exhaust dampers, as these will have a significant instructions and PM plans. I have included a generic PM
impact on comfort and energy. The basic function of an RTU schedule on a gas rooftop unit. There are many more items
is to supply conditioned air that returns back to the unit. that can expand the list, depending on the manufacturer
This cycle continues as long as the unit runs. If an outside and what the customer wants.
air damper is added, it will be used to bring in fresh air and Preventive maintenance may also need to be performed after
as an air-side economizer. In the case of the economizer, the hours. On one occasion, a service technician tried to clean the
conditions are just right to use outside air to cool the building condenser coil while the unit was running and the smell went
instead of using mechanical cooling. At this point the return through the outside air dampers, evacuating an entire office
dampers close. When the return dampers close, or bring in building in downtown Washington, D.C., which also brought
outside air, the building would over-pressurize. In this situa- out the hazmat team and the fire department—a lesson that
tion, the exhaust fan comes on and exhausts the air, keeping technician will never forget.