HVAC Maintenance Checklist: Prevent Breakdowns & Save Energy

HVAC Maintenance Checklist: Prevent Breakdowns & Save Energy

Maintenance Checklists
100 Items
Comprehensive HVAC maintenance checklist covering safety procedures, air filters, coils, drainage, blowers, refrigerant systems, electrical controls, and performance testing.

HVAC Maintenance Checklist

Complete HVAC maintenance checklist covering all essential heating, ventilation, and air conditioning system components including safety procedures, filter maintenance, coil cleaning, refrigerant system checks, electrical controls, and performance testing for optimal system efficiency and longevity.

1. Safety & Pre-Inspection Checks

1Lock out / tag out power supply (turn off breaker, isolate)
2Verify that service switch is off
3Ensure work area is clean, free of hazards
4Wear proper PPE (gloves, safety glasses, etc.)
5Check for signs of water, oil, or refrigerant leaks before touching components
6Verify presence and operation of CO / gas detectors (if applicable)
7Inspect wiring, conduit, junction boxes for damage or exposed conductors
8Confirm system is at rest (fans off, compressor off)
9Review maintenance history / past logs before starting
10Note ambient temperature and humidity as baseline

2. Air Filter & Airflow Management

1Inspect return air filters (check for dirt, clogging, damage)
2Replace or clean filters as needed
3Confirm filter size and correct orientation (arrow direction)
4Check for bypassed filters or unfiltered air return paths
5Inspect filter housing and gaskets for sealing integrity
6Assess airflow across filters (pressure drop, velocity)
7Clean pre-filters or screens if present
8Check for obstructions (curtains, furniture) in front of returns
9Confirm that supply registers and grilles are open and unobstructed
10Note scheduled filter replacement interval and set reminders

3. Coils, Condenser, and Evaporator Components

1Inspect evaporator coil for dust, debris, frost, corrosion
2Clean evaporator coil using approved cleaner
3Check the condenser coil for buildup (leaves, dirt, grime)
4Clean condenser coil with water or coil cleaner
5Inspect coil fins for damage and straighten bent fins
6Ensure proper drain of condensation from coils
7Inspect coil insulation (e.g. on suction lines) for deterioration
8Check for signs of refrigerant leaks near coil joints
9Verify that coil casing and housing are secure and closed
10Confirm adequate clearance around outdoor coils (at least 12–24 in)

4. Condensate Drains & Drainage System

1Inspect condensate drain lines for clogging or blockages
2Flush drain lines with water or appropriate chemical (e.g. bleach)
3Check primary and secondary drain pans for leaks or corrosion
4Verify that pan floats and overflow switches operate correctly
5Ensure proper slope on drain piping toward outlet
6Inspect trap (U-bend) is intact and full of water
7Confirm condensation exits building without backflow
8Check for condensation leakage around the system area
9Clean and disinfect pans and piping as needed
10Log last drain maintenance date

5. Blower, Fans & Ductwork

1Inspect blower motor, wheel, and housing for dust build-up
2Check blower wheel/impeller for damage or imbalance
3Clean blower wheel, housing, and blades
4Verify blower belt condition (cracks, wear) and tension (if belt-driven)
5Lubricate blower motor bearings if applicable
6Check blower amp draw against rated specification
7Inspect supply and return ductwork for leaks, damage, loose joints
8Check duct insulation integrity and repair where needed
9Verify that dampers and linkages operate and seal properly
10Inspect flex ducts for kinks, sagging, or disconnected joints

6. Refrigerant System / Cooling Cycle

1Inspect refrigerant lines for insulation damage, corrosion, or leaks
2Check refrigerant charge (pressure/temperature) vs design spec
3Verify subcooling / superheat (as appropriate)
4Inspect suction and discharge service valves for leaks
5Check for oil in sight glass (if applicable)
6Confirm proper operation of expansion device (TXV, capillary)
7Inspect filter drier or liquid-line filter for restrictions
8Check for abnormal vibration or noise in piping
9Ensure refrigerant piping is supported and vibration-damped
10Record refrigerant type, amounts, and pressures

7. Electrical & Control Systems

1Tighten all electrical connections (terminals, lugs, breakers)
2Inspect fuses, circuit breakers, and replace if damaged
3Test contactors and relays for proper function
4Check capacitors (run, start) with capacitance meter
5Measure voltage and amperage on motors (compressor, blower, fan)
6Inspect transformer(s) and control circuit wiring
7Confirm thermostat wiring and functions (sensors, communications)
8Check safety switches, interlocks, and limit devices
9Inspect low-voltage controls and wiring insulation
10Verify all control logic, and that the system cycles correctly

8. Heating / Combustion / Heat Exchanger (for systems with heat)

1Inspect burner assembly, flame sensor, igniter, and electrodes
2Clean burners and remove soot or carbon deposits
3Check heat exchanger for cracks, corrosion, or damage
4Test combustion (CO, O₂, CO₂, stack temp) per manufacturer spec
5Verify gas pressure and burner gas valve operation
6Inspect flue venting, flue pipes, and draft inducer
7Check for blockages or corrosion in venting system
8Inspect pilot or ignition flame stability
9Test safety devices such as limit switch, rollout sensors
10Confirm proper startup and shutdown sequences

9. Thermostat, Sensors & Controls

1Verify thermostat calibration (compare with independent thermometer)
2Test different modes: heating, cooling, auto, fan on/off
3Check thermostat placement (avoid direct sunlight, drafts)
4Inspect sensor wiring and connections
5Clean thermostat interior (if accessible)
6Ensure display, schedule, and programming function properly
7Test remote sensors or zone sensors (if present)
8Check control sequences, staging, and setpoints
9Log any software/firmware version or changes (smart thermostats)
10Confirm communication with central control / BMS (if applicable)

10. System Operation, Performance & Reporting

1Perform a full system startup and observe transitions
2Monitor system for unusual vibrations, noises, or cycling
3Measure temperature differences (ΔT) across coils
4Check supply and return temperature readings
5Verify overall system capacity/performance vs design
6Monitor electrical consumption during operation
7Document any defects, abnormalities, or recommendations
8Capture photographs or measurements for records
9Review warranty or past repair history before recommending parts
10Provide the customer / facility manager with report and schedule next service
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