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OPERATION&MAINTENANCEMANUAL

HVACSYSTEM(AIRSIDE)VRVAIRCONDITIONINGSYSTEM

6. MAINTENANCE

I M P O R T A N T : The material contained in this Section is designed as a general overview ofmaintenance requirements and may not contain answers for specific maintenance questions.

Consult the manufacturers instruction manuals, in BOOK-4 section 13 of this O&M forspecific maintenance information.

6.1 GENERAL

6.1.1 Maintenance Precautions

Personal Protective Equipment (PPE) Required!

Installing/servicing this unit could result in exposure to electrical, mechanical and chemicalhazards.

Before installing/servicing this unit, technicians MUST put on all Personal ProtectiveEquipment (PPE) recommended for the work being undertaken. ALWAYS refer to

appropriate MSDS and OSHA guidelines for proper PPE.

When working with or around hazardous chemicals, ALWAYS refer to appropriate MSDS and

OSHA guidelines for information on allowable personal exposure levels, proper respiratoryprotection and handling recommendations.

If there is a risk of arc or flash, technicians MUST put on all Personal Protective Equipment(PPE) in accordance with NFPA70E or other country-specific requirements for arc/flashprotection PRIOR to servicing the unit.

Failure to follow recommendations could result in death or serious injury.

WARNING Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow

proper lockout/tagout procedures to ensure the power can not be inadvertently

energized. Failure to disconnect power before servicing could result in death or

serious injury.

WARNING Contains Refrigerant!AVOID prolonged breathing of the vapor. Prolonged inhalation of refrigerant is

extremely dangerous; death can occur without warning

CAUTION

ALWAYS wear protective goggles when working with refrigerant. If liquid

refrigerant gets in your eye, permanent blindness may result

DO NOT allow refrigerant to come in contact with your skin. Refrigerant has a

very low boiling point, which will cause frostbite

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6.1.2 Maintenance Planning

Since maintenance work is generally done in the least time possible, maintenance activitiesshould be planned. In addition to ensuring that the necessary materials, tools, parts are

assembled and prepared for use in advance of the work, the maintenance activity plan

should also cover all aspects of the activity which may include the following.

Scheduling with operations

1. Site access

2. Calibrated test equipment for each test required

3. Necessary lighting, electrical power, and service air to perform the work

4.

Cleaning aids consisting of clean, white, lint-free cloths; solvents; vacuum cleaner;

and dry compressed air

5. Personnel safety equipment required for the specific maintenance activities beingperformed

6.1.3 Maintenance program

A total maintenance program for Hangar facility must contain elements of both preventiveand predictive maintenance. Preventive maintenance is the systematic care and servicing of

equipment and facilities to prolong their useful life. Predictive maintenance consists of theperformance of periodic equipment inspections to identify and monitor symptoms (such as

increasing wear, abnormal vibrations, or increasing power usage) which indicate that

mechanical failure of a piece of equipment may be approaching. The goal of predictivemaintenance is to develop an awareness of developing problems so that needed repairs can

be made on a planned rather than on an emergency basis and unscheduled system downtime resulting from unpredicted equipment failure is avoided. Effective execution of a total

site maintenance program requires the implementation of the following elements.

1. Training and instruction of maintenance personnel, operators, and users of the

particular equipment systems in proper operation, maintenance, and safetyprocedures.

2. Systematic, periodic inspection and servicing of plant systems and equipment by

skilled maintenance personnel.

3. Assignment of specific maintenance responsibilities to skilled maintenance personnel

and to operators of equipment.4. Continuing supervision of the site maintenance program.

5. Periodic utility systems maintenance inspections to ensure the maintenance program

is being implemented.

Only a regular and organized scheme of maintenance work, planed, to cover all details ofthe installation within given maintenance periods, can ensure continued satisfactory

operation with a minimum liability to interruption to supply due to equipment faults. Aplanned maintenance scheme should include a system of logging, wherein records are kept

on inspection, maintenance and repair of all items of plant and equipment.

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Careful attention must be given to securing the safety of personnel and equipment whilemaintenance or repair is in progress. A code of safety rules based on system permit to

work is recommended.

Where maintenance work in progress is in progress, a DANGER notice must always be

attached to any Live apparatus calling attention to the danger of approach, A CAUTIONnotice must always be attached to plant or its associated control equipment which may

occasioned by interference. Before any work is commenced on any items of equipment, thesupply and ancillary circuits must be isolated and locked off if possible.

Warnings!

In the event of a refrigerant leak, thoroughly ventilate the room. If refrigerant leaks and

comes in contact with an open flame, toxic gases will be generated.

After installation & maintenance work has been completed, check for refrigerant leaks.

Caution:

Do not touch the refrigerant pipes with bare hands during operation. The refrigerant

pipes are hot or cold depending on the condition of the flowing refrigerant. If you touchthe pipes, burns or frostbite may result.

After stopping operation, be sure to wait at least five minutes before turning off the

main power switch. Otherwise, water leakage or breakdown may result.

Do not use refrigerant other than R410A refrigerant. If another refrigerant is used, the

chlorine will cause the oil to deteriorate.

Use the following tools specifically designed for use with R410A refrigerant.

Gauge manifold

Flare tool

Charge hose

Size adjustment gauge

Gas leak detector

Vacuum pump adapter

Torque wrench

Electronic refrigerant charging scale

Be sure to use the correct tools. If dust, debris, or moisture enters the refrigerant lines,

refrigeration oil deterioration may result.

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OPERATION&MAINTENANCEMANUAL

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6.2 GENERAL MAINTENANCE

Inspection Action Frequency

Hangars and

Support

Inspect hangers and supports:

Check for corrosion, wear, and failed parts.

Make certain that all supports are in line withthe piping and tracking true,

Make certain that each hanger is carrying itsshare of the load; and that there are no signs

of imminent failure of any stressed member.

Yearly

Check the refrigerant piping for leaks and propersupport. Repair defective connections. 3 monthly

Check piping insulation to make sure the insulation

is still wrapped around piping. Repair or replace ifneeded.

3 monthly

Check piping for dents and frosting. Replace piping

section if dents are found.3 monthly

RefrigerantPiping

Check piping for unnecessary vibration, noise, and

wear. Repair and eliminate vibration and wear.3 monthly

Inspect outer surface for damage. Repair orreplace as necessary

Yearly

Insulation

Check integrity of vapors seals Yearly

Indoor Unit

Remove and clean air filter Monthly

Clean surfaces of casing 3 monthly

Brush or vacuum clean evaporator coil surfaces 3 monthly

Check for correct operation of control 3 monthly

Check fan is free to rotate 3 monthly

Check for unusual noise of vibration 3 monthly

Clean out drip tray and ensure condensate drain isfree from obstruction

3 monthly

Check unit for sign of leakage 3 monthly

Indoor UnitGeneral

Inspection

Check and maintain component items refer to

individual components maintenance scheduleVarious

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General Maintenance Continued

Inspection Action Frequency

Outdoor Unit

Inspect units for signs of leakage or corrosion

Clean of any deposits and treat any bare metal

accordingly

3 monthly

Clean condenser coil surfaces 3 monthly

Check fans are free to rotate and impellers aresecure onto shaft

3 monthly

Check operation of control 3 monthly

Check refrigerant charge 3 monthly

Check operation of crank case heater 3 monthly

Check crankcase oil level, top up as required 3 monthly

Check for unusual noise or vibration 3 monthly

Outdoor UnitGeneral

Inspection

Check and maintain component items refer toindividual components maintenance schedule

Various

6.3 COMPRESSOR

Inspection Action Frequency

Check compressor for sign of leakage Weekly

Check oil level Weekly

Check oil is contaminated with refrigerant Weekly

Check for unusual noise or vibration Weekly

Inspect compressor for sign of corrosion Yearly

Check security of electrical connection Yearly

Compressor

Check and maintain component item (Electric

Motor) refer to individual componentmaintenance schedule.

Various

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6.4 FILTER

Caution:

Do not dry the filters in direct sunlight or by using a heat source, such as an electric

heater: this may warp them.

Do not wash the filters in hot water (above 50C), as this may warp them.

Make sure that the air filters are always installed. Operating the unit without air filters

can cause malfunction.

Caution:

In removing the filter, precautions must be taken to protect eyes from dust. When the filter is removed, do not touch the metallic parts inside the indoor unit,

otherwise injury may result.

Inspection Action Frequency

Take the manometer reading, If the reading shows

the filter cells are at their maximum pressuredrops, they should be washed. After washing

check the condition of filter medium, if damagedreplace.

MonthlyFilter

Wipe any accumulated dirt from the retaining

channels and frames

Monthly

Note : On replacing access doors check that the integral seals give a good air seal, if

not, replace seals

Please refer to manufacturer literature on sections 13.4, 13.5, 13.6, 13.7 of this

manual for filter removal & cleaning proof particular models

6.5 COOLING COIL

Inspection Action Frequency

Check pipe work connection for leak 3 Monthly

Check coil matrix is clean, unobstructed and airflow is evenly distributed over coils

3 Monthly

Check condensate drain pans and connection areclear. Check drain pipe is properly attached

3 MonthlyCooling Coil

Clean Coil Matrix, Use soft brush and mild

detergent solution, If heavily contaminated withgrease use steam lance, Take care not to damage

or distort fins

6 monthly

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6.6 FAN

Inspection Action Frequency

Check fan is running smoothly without excessive

noise or vibrationDaily

Check flexible connection are secure and airtight Weekly

Check that fan guards is clean and unobstructed Weekly

Check anti-vibration mountings / hangars are

secure, free to move and in good conditionMonthly

Check impeller and shaft for freedom of movementand balance 6 monthly

Clean and check casing internally and externally,

repair any corrosion or damage to finish found.

Check all bolted joints are secure

Yearly

Fan

Check and maintain component items (electricmotor) refer to individual components

maintenance schedule

Various

6.7 ELECTRIC MOTOR

Important:Always ensure that electrical supply to the motor is positively isolated

before carrying out any operation

Inspection Action Frequency

Generally check motor to ensure casing ventilation

louvers are unobstructed, alignment is correct,holding down bolts and pulley/couplings are

secure, and motor without excessive vibration,

temperature and noise.

Monthly

Totally enclosed motors only-Check that casingdrain holes are unobstructed or if plugged, remove

plugs to drain off any accumulated condensation.

Monthly

Check motor terminals are secure, cables show nosigns of overheating, terminal box is internally dryand clean, and cover is refitted securely

6 monthly

Check that insulation resistance across winding isat an acceptable value

6 monthly

Check centrifugal switch for wear and action 6 monthly

Check drawn full load current does not exceed

value stated on the name plate6 monthly

Electric Motor

Dismantle and overhaul motor in accordance with

manufacturer recommendations3 yearly