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HVAC Predictive Maintenance: The Future of HVAC Businesses

This article has been reviewed by Billy Stevens for accuracy.

When thinking about HVAC maintenance, your mind may go first to reactive maintenance. Also known as corrective maintenance, this involves fixing broken equipment and replacing old parts. In other words, it’s maintenance after the issue has occurred. However, there’s another approach expected to take the industry by storm in the coming years — HVAC predictive maintenance. Learn more about predictive maintenance and how it applies to HVAC systems. 

What Is HVAC Predictive Maintenance? 

Predictive maintenance is an innovative approach that evaluates potential issues that may arise with HVAC equipment and systems before they occur. It guides when technicians should perform maintenance tasks to avoid breakdowns and disruptions, as well as extend the life of the machinery. With heating, ventilation, air conditioning, and refrigeration systems, the main goal is predicting when equipment failure is most likely to happen.

How Does Predictive Maintenance Work? 

A range of technologies come together to perform predictive maintenance. These include artificial intelligence (AI), the Internet of Things (IoT), and predictive analysis. IoT platforms gather data from sensors connected inside HVAC systems and transfer the information into databases, typically enterprise asset management (EAM) systems or computerized maintenance management systems (CMMS). 

AI and machine learning algorithms analyze this data in real time, creating a detailed report of the equipment’s current condition. When potential problems are identified, the technology sends alerts to the maintenance team. Machine learning algorithms also make informed predictions about the future condition of equipment. This feature not only empowers more efficiency with maintenance activities but can also enhance other processes, like service scheduling and inventory management.

Predictive Maintenance vs. Preventive Maintenance

Preventive maintenance is the precursor to predictive maintenance. Preventive maintenance looks at the history of equipment performance to make informed estimations about its condition. Compare this with predictive maintenance, which uses technology to determine the actual condition of the equipment.

There are some pitfalls with preventive maintenance. For one, it creates the possibility of unnecessary inspections and repairs, which can be costly. It also isn’t proactive in detecting part failures, which can result in unplanned downtime and more extensive repairs. Predictive maintenance is the more cost-effective, less labor-intensive alternative to preventive maintenance.

HVAC Predictive Maintenance and Vibration Analysis 

Sensor technology and data analysis are at the core of HVAC predictive maintenance. Vibration sensors are critical to this process as they provide insight into key components of HVAC systems, such as blowers, compressors, and fans. Discover the role vibration analysis plays in HVAC predictive maintenance. Sera Table Design

Vibration Sensors 

Vibration sensors measure vibration level and frequency in equipment and parts. Components like compressors and pumps produce unique vibration patterns when operating properly. They detect changes in vibration patterns, which might suggest a malfunction. Vibration sensors perform fault detection without causing operational disruptions.

Vibration Analysis 

Vibration analysis is interpreting data collected from sensors. While sensors identify a possible issue, vibration analysis pinpoints the specific problem. Advancements in digital technology have enhanced vibration analysis. For example, HVAC contractors may use software to evaluate vibration data in real time and predict when equipment failure might occur.

Benefits of Predictive Maintenance 

The data-driven approach of predictive maintenance provides many advantages for HVAC contractors. Consider the following reasons to invest in a predictive maintenance strategy:

Lower Maintenance Costs 

Advanced diagnostics means potential problems are caught in the earliest stages. Repairs are easier and less expensive, and instances of unnecessary repairs drop. 

Improved Energy Efficiency 

By quickly identifying and correcting smaller issues before they become major problems, predictive maintenance boosts system performance. The result is less energy consumption for greater sustainability.  

Increased Equipment Lifespan 

Even though many issues can be repaired, wear and tear can cut short the lifespan of equipment over time. Predictive maintenance supports the optimal performance of these systems, allowing them to reach their full life expectancy. 

Reduced Downtime 

When breakdowns happen, disruptions are sure to follow. Predictive maintenance increases the likelihood that systems run continuously, lowering the risk of downtime. 

Enhanced Indoor Air Quality 

Poor air quality is a primary consequence of equipment failure. When potential issues are identified and corrected sooner, inhabitants experience better air quality, as well as airflow and temperature control. 

Cost Savings 

All these benefits contribute to cost savings. They can cut down on operating costs, which means lower energy bills. Regular maintenance may also cost less. 

Predictive Maintenance Use Cases 

HVAC systems feature multiple parts, so contractors may wonder if predictive maintenance is useful for identifying all potential issues, or only those central to operation, like compressors and fans. Part of what makes predictive maintenance so valuable is it responds to various maintenance needs, including: 

  • Dirty air filters 
  • Heat pump malfunctions 
  • Cabinet and refrigerant leaks 
  • Electrical connections 
  • Drain blockages 
  • Frozen coils 
  • Duct system issues 
  • Thermostat malfunctions 
  • Dysfunctional chillers 
  • Valve failure

The Future of Predictive Maintenance 

Since predictive maintenance relies on technologies subject to frequent innovation, it’s bound to continue evolving. Advancements in sensor technology and data analytics will make predictive maintenance more accurate and cost-effective. IoT wireless technologies may increase the energy efficiency and range of sensors, and machine learning algorithms contribute to resource optimization and precision with maintenance schedules.

Specific technologies advancing the role of predictive maintenance include: 

  • IoT-enabled predictive maintenance 
  • Digital twins 
  • Robotic inspection automation 
  • Predictive maintenance-as-a-service 
  • Immersive technologies like augmented reality (AR) and virtual reality (VR)

Impact of HVAC Predictive Maintenance on HVAC Memberships 

There is another great advantage of predictive maintenance — it can help boost memberships. HVAC contractors not only use data to make predictions about the types of repairs and maintenance that systems might need soon. They can also look at a homeowner’s service history to help determine which may benefit from a membership. 

HVAC memberships are critical for business growth, especially in the earlier stages. They often enable contractors to secure year-round work, a common challenge for field service businesses. Leveraging insight from predictive maintenance and membership management software, contractors can provide multiple quote options showing member and non-member pricing for the same services. This helps homeowners understand the cost savings of becoming a member. 

Of course, this is only possible with software that enables such advancing quote-building capabilities. Sera’s field service management software supports membership growth with a  multi-quote presentation that highlights membership savings. 

Hear from one of our customers to see the possible impact of predictive maintenance and FSM software on membership management in this case study

Improve HVAC Service Delivery with FSM Software 

HVAC contractors should invest in predictive maintenance to meet changing industry demands and deliver better customer service. In addition to IoT, AI, and other technologies enabling better HVAC predictive maintenance, contractors may also consider field service management software

FSM software uses automation to promote operational efficiency with tasks like scheduling, dispatching, and invoicing. It also provides HVAC techs and office staff with the data they need to provide more personalized service to customers, such as recommending maintenance and repairs based on service history. 

Sera offers HVAC service software based on the four pillars essential to better efficiency for small and medium-sized residential contractors. It features an automated Admin Portal, an intuitive Tech App, and the industry-first Customer Hub. Many field service businesses, including residential plumbing and electrical contractors, rely on Sera’s software to help them identify and remove inefficiencies and boost the bottom line. 

To learn more about predictive maintenance and field service management software, check out our Resource Center

You can also contact us today for a 15-minute discovery call or a 45-minute demo.

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