The Most Comprehensive HVAC Safety Checklist

Commercial field technicians need to always consider HVAC safety first and foremost. Whether you’re on a regular inspection, servicing as part of an ongoing maintenance contract, starting a small residential project, or about to enter the doors of your biggest commercial project yet, safety should always be top of mind. 

Many, if not most, contractors have their own set of HVAC safety procedures to go through, but not all of them have systematically ingrained them into their workflows. One way contractors use BuildOps is to do exactly that: Make safety a consistent and orderly part of their every workflow. And our mobile app even has custom forms and gated workflows to facilitate this safety and consistency across every job. 

You can customize these forms to be HVAC safety checklists for different types of equipment, installs vs. repairs, or even as a COVID-19 questionnaire to confirm your techs are cleared to work. Whatever system you’re using to create a safe workspace, you want to make sure everyone is on the same page.

We put together this HVAC safety checklist as either a good place to start or a new way to look at optimizing your existing processes. Not only does it keep things running smoothly, but the reminder to cover these tasks could also save you a costly second truck roll.

Electric Furnace

An electric furnace has several parts, including fuses, motors, and blowers that can overheat or malfunction if left uninspected for a long time. This checklist helps ensure everything is operating as it should. 

1. Check the fuses
2. Check the limit switches
3. Ensure that the sequencers are working properly
4. Check the heat strip amp draw
5. Ensure continuity of the heat strips
6. Check the blower motor amps
7. Check for low voltage wiring
8. Inspect the line voltage wiring
9. Clean or replace the media filter/clean the electronic air cleaner
10. Check the thermostat programming and operation
11. Cycle the equipment to ensure it is working
12. Prepare a diagnostic report of the findings

Gas Furnace

A gas furnace has more parts than its electric counterpart. Apart from the heat exchange system, it also has burners that need to be in good working condition. Gas pipes can be a fire hazard if slightly damaged, and they require regular inspection and maintenance.

1. Check the wiring and control circuit
2. Check the blower assembly
3. Physically inspect the heat exchangers
4. Check and adjust the air and fuel mixture
5. Inspect the venting and combustion air
6. Check the clean sensor and the flame rectification system
7. Inspect and adjust the inlet and outlet gas pressure
8. Check for gas leaks
9. Inspect the safety controls
10. Check the electrical components
11. Inspect the temperature rise in the dry bulb
12. Check the flue temperature and draft
13. Check the motor amps
14. Clean the burners, control panel, and then wipe down equipment
15. Inspect the supply and return static air pressures
16. Check the correct voltage for furnace equipment
17. Test and measure carbon monoxide levels
18. Check thermostat programming and operation
19. Clean or replace media filter/clean the electronic air cleaner
20. Cycle the equipment to ensure that it is working
21. Prepare a comprehensive diagnostic report of the findings

Ductless Mini Split

Ductless mini splits are air conditioners or heaters that consist of an outdoor air compressor and an indoor heat regulation unit. HVAC safety best practice dictates that the wiring and control systems should be regularly inspected and maintained.

Outdoor Unit

1. Check and clean the outdoor condensing unit
2. Inspect the indoor coil
3. Check for refrigerant leaks
4. Check the refrigerant lines and flare connections
5. Inspect the wiring and the control unit
6. Check all the electrical components
7. Ensure that all the equipment has the correct voltage
8. Check and clean the blower wheel
9. Wipe out the equipment
10. Check and clean the fan blade
11. Check the safety controls
12. Cycle the equipment to ensure it is working
13. Prepare a diagnostic report of the findings

Indoor Unit

1. Check if the remote is working and charge the batteries if need be
2. Inspect and clean the filters
3. Check and clean the blower wheel
4. Check and clean the indoor housing
5. Inspect and clean the condensate line
6. Check and clean the indoor coil
7. Ensure the condensate pump is working
8. Ensure that the voltage and communication systems connecting the equipment is working
9. Flush the drain line
10. Check the flare connections and the refrigerant lines
11. Check and clean the louvers
12. Cycle the equipment to ensure that it is working
13. Prepare a diagnostic report of the findings

Air Conditioners & Heat Pumps

Both systems use compressed refrigerant to collect heat from inside your home as air passes over the coil in the air handler and transfers it outside. Air conditioners and heat pumps are relatively similar, with the only difference being heat pumps can reverse themselves to provide heating when it is cold (compared to ACs, which can only cool spaces). They both have several intricate parts requiring regular inspection and maintenance, especially during this time when most HVAC technicians are expecting a surge in demand. 

1. Check and clean the outdoor condensing unit
2. Inspect the indoor coil
3. Check for refrigerant leaks
4. Check the condensate drain pan
5. Inspect the condensate p-trap and drain line
6. Check the control unit and the wiring
7. Inspect the blower assembly
8. Check the thermostat programming and operation
9. Inspect the suction and discharge pressure
10. Check the static air pressures of the supply and return
11. Check the safety controls
12. Inspect all the electrical components
13. Check the temperature drop and rise in the heat pump
14. Ensure that the superheat or sub-cooling is correct
15. Inspect the motor amps
16. Clean the control panel
17. Verify that all the equipment has the correct voltage
18. Check the blower speed
19. Check the refrigerant lines
20. Cycle the equipment to ensure they are working
21. Clean or replace the filter
22. Prepare a comprehensive diagnostic report of the findings

Make-Up Air System

Make-up air systems pull air from the outside to replace the hot air that has been expelled. They have several movable parts that need regular inspection.

1. Ensure the fan hood triggers the system
2. Check the heat strip amps
3. Inspect the current sensor installation and wiring
4. Check the current sensor settings
5. Check the condition of the blower wheel
6. Wipe down the equipment
7. Change the filter
8. Check thermostat programming and operation
9. Cycle the equipment to ensure it is running properly
10. Prepare a written diagnostic report of the findings

Hot Water Tank

Hot water tanks have burners that need regular inspection. They also have several valves and pipes that are prone to blockage and rust over time, which, left untreated, can be costly and highly complicated to replace. Regular inspection ensures they are in good shape.

1. Check the hot water temperature
2. Check the flame visibility and performance
3. Check the temperature settings of the tank
4. Inspect and clean the burners
5. Inspect the system for leaks and rust
6. Check the operations of the relief valve
7. Inspect the venting system
8. Drain around 5 gallons of water from the drain valve
9. Ensure that the earthquake straps are tight and intact
10. Wipe down the equipment
11. Cycle the equipment to ensure that it is working properly
12. Prepare a written diagnostic report of the findings

Tankless System

Tankless systems are water heating systems that heat water on demand. They have many sensitive parts that need regular inspection.

1. Check the hot water temperature
2. Check flame visibility and performance
3. Inspect and clean the burners
4. Inspect and clean the flame sensor
5. Check and clean the spark rod
6. Inspect and clean the inlet filter
7. Ensure that the relief valve is working properly
8. Inspect and investigate fault codes
9. Inspect the venting system
10. Flush the system with white distilled vinegar
11. Clean the equipment with pressurized air
12. Wipe down the equipment
13. Cycle the equipment to ensure that it is working properly
14. Prepare a written diagnostic report of the findings

COVID Safety

Lastly, we now know that COVID-19 is a respiratory infection that spreads via aerosol contact with infected persons and not fomite transmission. Still, field technicians are likely touching many different parts and speaking with several points of contact on the job site so care must be taken in the interest of HVAC safety.

1. Wash your hands with hand sanitizer and soap when in public spaces
2. Avoid close contact by keeping a 6-foot distance from others
3. Cover your nose and mouth with a mask at all times, when indoors
4. Ask yourself if you’re feeling flu-like symptoms, or have felt them in the last 14 days

BuildOps provides an all-in-one software for commercial contractors. Our HVAC software solution enables you to automate administrative and technical processes and monitor project progress. Maintaining high safety standards is just the beginning. Contact us for a free demo to see if we can amplify what your enterprise can handle.