HVAC controls retrofit and system troubleshooting
With Pentillion Construction, I helped audit, explain, and coordinate upgrades to an older HVAC control system. The building had existing controls and hardware that could not simply be replaced all at once, so the project needed a clear understanding of what was already there before the new work could be planned.
Understanding the old system before replacing parts of it
My role was to bridge the gap between the existing controls, the HVAC contractor, the controls contractor, and the practical needs of the building. I reviewed and documented how the system operated, helped explain the existing logic, and supported the retrofit so new equipment could be integrated without losing compatibility with parts of the older setup.
The upgrade included four new heat pumps. Because I had built much of the internal understanding of the existing controls, I became a practical reference point during the work. The value knowing what equipment was present and helping the contractors understand how the old controls, operating logic, and building requirements fit together.
Troubleshooting the shaking air handlers
That same system knowledge carried into troubleshooting. The building had two large air handlers that were shaking under certain operating conditions, and the cause had not been identified.
One proposed path was to bring in an engineering audit to measure resonant frequencies using specialized equipment. That may have been needed eventually, but before jumping to that step, I worked through a more direct inspection of the system.
Looking for the real field condition
I checked likely mechanical causes, including whether the air-handler shafts appeared to be off balance, the dampening system, and used a 360 camera and thermal imaging camera to inspect areas that were difficult to access directly.
That investigation pointed toward a loose sheet-metal wall dividing the large duct that supplied hot and cold air to the building. Under certain airflow and pressure conditions, the loose partition deflected until it relieved the pressure differential, then snapped back, allowing the pressure to rebuild and repeat the cycle. This created a low-frequency pulsation that transmitted vibration into the air-handler area and surrounding building structure.
A logical conclusion
I documented the old controls, identified what still had to work, coordinated the contractors around the real operating logic, and investigated the field condition before assuming the next step had to be expensive or abstract.
The result was a building system that became easier to explain, upgrade, maintain, and hand off.
Custom glass awning redesign and installation
With Pentillion Construction, I delivered a custom glass awning replacement where the design intent was clean and visually simple, but the existing building made the installation much more complicated than the drawings suggested.
The project replaced existing vinyl awnings with a suspended glass canopy system supported by steel outriggers and diagonal tie rods. The challenge was making that system work on the real building, with the right tolerance, alignment, drainage, serviceability, and installation sequence.
The hidden structure did not match the clean drawing
The upper tie-rod anchors were intended to connect back to the structural concrete spandrel beam, but that beam was hidden behind exposed-aggregate precast architectural panels with an inconsistent air gap behind them.
That changed the problem. The anchors could not simply be fastened as drawn, and the inconsistent gap made it difficult to scan the structure and confidently locate reinforcing steel before drilling. The installation needed enough field tolerance to avoid reinforcement while still leaving the finished awning visually aligned from the street.
Making the anchorage adjustable without looking like a fix
I helped investigate the existing condition and separate what was architectural cladding from what was part of the structural load path. That understanding shaped the redesign of the upper anchorage.
The detail needed to bridge through the architectural panel, connect back to the structure, and still allow the installer to shift final anchor locations where needed. The exposed cover plates then had to conceal that adjustment zone without looking like an afterthought.
The tie rods also had to stay visually aligned even when the hidden anchors had to move. The connection evolved toward a more adjustable arrangement using clevises and paired plates, with practical details such as wrench flats and opposite-handed threading so the rods could be adjusted in place.
Letting the glass layout respond to the building
The lower outriggers created another coordination problem. Their locations needed to avoid likely reinforcement while still supporting the glass layout. With the architect’s approval, the glass panel widths were allowed to vary within a controlled range so the steel supports could respond to the real structure instead of forcing a layout that was difficult to install.
The glass support detail also had to be reconsidered. A more fixed pressure-plate approach would have made installation and future service more difficult, especially if individual panels ever needed to be removed. Working with the installer, we moved toward a more serviceable approach that better suited how the glass would be handled, installed, and maintained.
Designing the corner so it could actually be fabricated
The corner conditions added another layer of practical design work. The corner framing had to coordinate glass sizes, steel fabrication, galvanizing, fit-up, and installation sequence.
I raised concerns about field welding galvanized steel and helped move the approach toward details that could be fabricated and installed more predictably. When galvanizing distortion became a concern, I helped look for a simpler framing approach that better matched the typical outriggers and reduced the risk of a distorted corner assembly.
Turning layout into a repeatable field process
A major part of my contribution was turning the layout problem into something the installer could repeat in the field. Because the outrigger and standoff locations varied along the building, there was no simple continuous datum for every cored opening.
I designed and 3D printed a positioning jig that sat on the installed outrigger and held a laser-cut template board for the core-hole locations. The template allowed the layout to shift when needed to avoid reinforcement while maintaining the relationship between the outrigger, standoff, and tie rod.
Dealing with drainage after the slope changed
The project also had to respond to drainage requirements. A late requirement changed the awning slope so water drained back toward the building rather than away from it.
That meant reviewing tie-rod geometry, glass slope, flashing, and gutter details so the finished system could manage water without creating maintenance or building-envelope problems. I helped develop a custom gutter approach that could be installed with the completed steel and glass while remaining serviceable and cleanable.
Keeping the work moving on site
Alongside the design and coordination work, I supported day-to-day site execution. That included coordinating with the architect, structural engineer, fabricators, glass contractor, sheet metal contractor, crane company, tenants, and site team; helping maintain scaffold access; developing site-specific safety procedures; removing existing awnings and flashing; coordinating electrical and signboard-related work; reviewing layout; resolving field discrepancies; and checking installation details as the work progressed.
A clear vision
The finished awning looks clean because we solved a lot of messy problems before they became visible. Hidden structure, reinforcement risk, anchor tolerance, glass layout, galvanizing, drainage, installation access, and future service all had to be handled together.
This project shows how I work between drawings and the field. I ask how an idea will be located, fabricated, adjusted, installed, drained, maintained, and handed off.
Enterphone data recovery and audio repair
A building’s Mircom TX3 enterphone failed, and the first risk was not just getting the hardware working again. The resident directory and system configuration also needed to be protected. Replacing the controller board without recovering the data could have turned a hardware failure into a larger setup and handoff problem.
I traced the failure through the power supply, transformer, door strike circuit, phone line, and controller board. The likely failure was in the board’s low-voltage power section, where a small surface-mount capacitor had burned.
Instead of immediately replacing the board and losing the configuration, I powered the damaged board with a current-limited DC bench supply. That let me bring the board up carefully, confirm that the internal 5V and 3.3V logic rails were stable enough to communicate, connect to the TX3 software, and recover the resident names and configuration before replacing the board.
After the new board was installed, I updated the configuration and verified the building functions tied to the panel. That included the postal lock input, door strike operation, grounding, phone-line settings, and relay behaviour. The goal was to leave the system in a known working state, not just swap the failed component.
There was also a call-audio issue where the caller’s voice became quiet after the call connected. I tested microphone gain, speaker level, DTMF sensitivity, and echo-reduction profiles. The issue appeared to be aggravated by sound reflecting inside the panel and around the speaker/microphone assembly, which could cause the echo reduction to clamp down unnecessarily.
I repaired and sealed the broken speaker enclosure and started working on a simple acoustic treatment around the microphone to reduce reflected traffic noise. It was a small repair, but it reflected the same troubleshooting approach as the board recovery: trace the system, protect the important data, verify the handoff, and keep looking when the first fix does not fully solve the user experience.
Fridge circulation fan
My Danby all-fridge was freezing food on the lower shelf while the rest of the cabinet stayed at a normal temperature. The drain was clear, and the fridge appeared to be operating normally, so the problem was not obvious from a standard check.
I used a thermal camera to look at what was actually happening inside the cabinet. The images showed cold air pooling near the lower back of the fridge. The unit relied mostly on natural convection rather than a built-in circulation fan, so the coldest air was not mixing evenly through the cabinet.
The fix was a small targeted airflow improvement rather than a major appliance modification. I added a low-voltage fan on a custom 3D-printed bracket to gently circulate air through the cabinet. I also added a small thermal switch attached to the compressor so the fan only runs when the fridge is actively cooling.
The result was a more even temperature distribution and a practical fix for a frustrating problem. It is a small project, but it shows a useful pattern: diagnose the actual system behaviour, avoid unnecessary complexity, and make a targeted physical improvement that matches the real failure mode.
And now I have no excuse not to eat my vegetables.
