04 FY21 DRC NEW HVAC Service Contract Appendices.pdf

8.0 REGULAR MAINTENANCE ITEMS

8.1 Air Filters

Filters should be checked on a regular basis and changed when they become dirty. This will ensure effi cient operation of the unit. Spare fi lters should be kept in stock as these tend to be a frequently replaced maintenance item. Filters may require changing as often as monthly. Note also that construction dust on new installations will quickly clog new fi lters.

The optional Mini DAP II or Mini DAP III control panel can monitor fi lters with an optional dirty fi lter alarm. Although the unit may have a dirty fi lter alarm, this should not be relied on as the only determinant for replacing fi lters. A mis-adjusted fi lter differential pressure switch may not give a proper indication of a clogged fi lter.

To check the fi lter differential pressure switch for proper adjustment, temporarily cover about 75% of the return air opening using heavy cardboard or similar material. The alarm should energize when 75% of the air is blocked, simulating dirty fi lters. If the alarm energizes prematurely or does not energize at all, the pressure switch should be adjusted. Panels must remain closed when determining if an adjustment is necessary.

Filters that require changing can restrict airfl ow and create problems such as coil icing or poor air distribution.

8.2 Belts

Belt tension should be checked regularly (monthly) to ensure proper tension. If tightening is required, loosen the four motor mounting bolts. Turn the adjustment screw on the end of the motor mounting channel until the proper belt tension is attained. Retighten the four mounting bolts. Damage can occur to belts that are overtightened. The amount of play in a typical driveset should be 1/2 inch.

When tightening the belts make sure the pulley alignment is true. If the belts are over tightened or if the pulleys are mis-aligned the bearing life and belt life is shortened considerably.

8.3 Bearings

Bearings used on Mini Ceiling units are permanently lubricated and do not require maintenance.

8.4 Humidifi er Canisters

The optional steam generator type humidifi er does not require maintenance other than to replace the canister as required. This frequency will depend on usage and water type. A set of manufacturer’s instructions for the humidifi er is sent as part of the paperwork placed inside the unit when it ships.

8.5 Fuses

Always replace fuses with those of the equivalent rating with regard to: 1) amperage, 2) voltage, and 3) speed. For instance compressors and motors are inductive loads which require time delay fuses. Electric reheat and humidifi ers are resistive loads requiring fast acting fuses.

8.6 Heating Elements

Heating elements do not normally require maintenance. However sometimes they may accumulate a fi lm of dust or dirt when unused for extended periods of time. When energized, the burning debris can create smoke or unpleasant odor. To help avoid this, periodic cleaning is recommended.

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8.7 Refrigerant Filter Drier

Factory installed refrigerant fi lter driers do not normally require maintenance. When replacing compressors or other repairs that open the refrigeration system to atmosphere, it is advisable to replace the fi lter drier. The equivalent type and size should be used.

Data Aire, Inc.

Monthly Maintenance Inspection Checklist

Model No. __________________ Serial No. ____________________ Prepared by: _______________ Date: ___ / ___/ 200__

Air Filters ___ Check for restricted air fl ow

Blower Section ___ Blower wheel free of debris moves freely ___ Check belt tension and condition ___ Bearings in good condition ___ Check pulleys and motor mounts

Air Distribution Section ___ Check for restriction in grille(s)

Compressor ___ Check for leaks

Refrigeration Cycle/Section ___ Check crank case temperature

Air Cooled Condenser (if applicable) ___ Condenser coil clean ___ Motor Mounts tight ___ Motor fan bearings in good condition ___ Refrigeration lines properly supported

Water/Glycol Fluid Cooler (if applicable) ___ Water regulating valve function ___ Check for water/glycol leaks (piping area)

Glycol Pump(s) ___ Glycol leaks (pump area) ___ Pump operation ___ Auto air vent clean of mineral deposits

Condensate Drain and Pump (if applicable) ___ Check for water leaks ___ Check for restricted air fl ow ___ Pump operation

Steam Generating Humidifi er ___ Check canister for deposits and water level ___ Check condition of steam hose and clamps

Electrical Panel ___ Check contactor operation ___ DAPII control panel operations

Equipment Runtimes Blower _________ hrs Condenser _________ hrs Compressor _________ hrs Reheat _________ hrs Humidifi er _________ hrs Dehumidifi cation _________ hrs Energy Saver _________ hrs

___ Reset all to read zero runtimes

Temperature/Humidity set at: ___° ___% RH

Notes: ______________________________

Data Aire, Inc.

Quarterly Maintenance Inspection Checklist

Model No. _______________________ Serial No. ___________________________ Prepared by: _____________________ Date: ___ / ___/ 200__

Air Filters ____ Check for restricted air fl ow ____ Check fi lter differential switch ____ Wipe fi lter rack section clean

Blower Section ____ Blower wheel free of debris and moves freely ____ Check belt tension and condition ____ Bearings in good condition ____ Check air fl ow safety switch operation ____ Check pulleys and motor mounts

Air Distribution Section ____ Check for restriction in grille(s)

Compressor ____ Check for leaks

Refrigeration Cycle/Section ____ Check for moisture (site glass) ____ Check suction pressure ____ Check discharge pressure ____ Check hot gas bypass valve operation ____ Check thermostatic expansion valve operation ____ Check solenoid valve operation

Air Cooled Condenser (if applicable) ____ Condenser coil clean ____ Motor mounts tight ____ Motor fan bearings in good condition ____ Refrigeration lines properly supported ____ Heated receiver site

Water/Glycol Fluid Cooler (if applicable) ____ Water regulating valve function ____ Check solution _____% ____ Check for water/glycol leaks (piping area) ____ Water/Glycol fl ow switch operational

Glycol Pump(s) ____ Glycol leaks (pump area) ____ Pump operation ____ Auto air vent clean of mineral deposits

Condensate Drain and Pump (if applicable) ____ Check for water leaks and restricted fl ow ____ Pump operation

Steam Generating Humidifi er ____ Check canister for deposits and water level ____ Check condition of steam hose and clamps ____ Check drain and fi ll valve for deposits

Reheat ____ Check reheat element(s) for dust ____ Check high limit switch operation

Electrical Panel ____ Check fuses ____ Check contactor operation ____ Check all electrical connections ____ Check operation sequence ____ Check calibration of change over thermostat (Energy Saver System Only)

Equipment Runtimes Blower ____________ hrs Condenser ____________ hrs Compressor ____________ hrs Reheat ____________ hrs Humidifi er ____________ hrs Dehumidifi cation ____________ hrs Energy Saver ____________ hrs

____Reset all to read zero runtimes

Temperature/Humidity set at: _____° _____% RH

Notes: _____________________________________

Preventive Maintenance

The operating life of the DAFC fl uid cooler can be extended by following a simple preven-tive maintenance schedule. This schedule will reduce the possibility of failure of compo-nents and unnecessary malfunction of the system. Although the service technicians must be thoroughly familiar with the special design features of this equipment before attempting any service or repair, an inexperienced technician can perform certain simple maintenance functions to assure normal, trouble-free operation.

Maintenance Functions

Monthly

Check heat exchanger for obstruction to the inlet air side of coil.

Bleed air from glycol system.

Seasonally

Check electrical components for loose wire connections.

Check contactor contacts for pitting.

Check glycol solution level in the system.

Check fan motor(s)

Bi-Annually Check the glycol solution inhibitors. Inhibitor level prevents corrosion and glycol concentration prevents freezing. Flush as necessary.

Clean the coil.

Annually Check the glycol system for leaks and corrosion.

WSHP-SVX01L-EN 101

Maintenance

Preventive Maintenance

Maintenance on the unit is simplified with the following preventive suggestions:

Filter maintenance must be performed to assure proper operation of the equipment. Filters should be inspected at least every three months, and replaced when it is evident they are dirty. Filter sizing is shown in Table 57, p. 101:

Check the contactors and relays within the control panel at least once a year. It is good practice to check the tightness of the various wiring connections within the control panel.

A strainer (60 mesh or greater) must be used on an open loop system to keep debris from entering the unit heat exchanger and to ensure a clean system.

For units on well water, it is important to check the cleanliness of the water-to-refrigerant heat exchanger.

Should it become contaminated with dirt and scaling as a result of bad water, the heat exchanger will have to be back flushed and cleaned with a chemical that will remove the scale. This service should be performed by an experienced service person.

It should be noted that the water quality should be checked periodically. See Table 58, p. 101.

Condensate Trap

For units incorporating a negative trap design, ensure that the condensate system is primed with water at all times.

Allowing a negative, pressure condensate system to run dry could cause a break in the condensate seal allowing the fan to draw water from the condensate line to spray moisture into the mechanical system. By maintaining a primed condensate trap, a seal will be created and will help prevent these complications.

WARNING

Hazardous Service Procedures!

The maintenance and trouble shooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnects before servicing.

Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components per these tasks. Failure to follow all of the recommended safety warnings provided, could result in death or serious injury.

Table 57. Filter sizing

Size (60 Hz) Size (50 Hz) Filter Size (Actual) inches (mm)

GEH

006-015 006-012 14 5/8 x 20 ¼ (371 x 514)

018-030 015-024 17 7/8 x 23 7/8 (454 x 607)

036-042 030-036 18 5/8 x 25 3/8 (473 x 645)

048-060 042-060 20 5/8 x 29¾ (524 x 755)

072-120 072-090 20 x 25 (3) (508 x 508)

150-180 120-150 25 x 25 (3) (635 x 635)

GEH/GEV

018-030 015-024 17 3/8 x 23 5/8 (441 x 600)

GEV

006-015 006-012 15 7/8 x 19 7/8 (403 x 504)

018-032, 040 015-024 17 7/8 x 24 7/8 (454 x 632)

036-042 030-036 19 7/8 x 24 7/8 (504 x 632)

048-060 042-060 27 7/8 x 29 7/8 (708 x 759)

GEV 072-120 090 20 x 20 (4) (508 x 508)

150-300 120-240 19 5/8 x 24 5/8 (6) (498 x 625)‘

EXH

018-024 — 17 7/8 X 23 7/8 (454 X 607)

030-036 — 18 5/8 x 25 3/8 (473 x 645)

042-070 — 20 5/8 x 29 3/4 (524 x 755)

EXV

018-024 — 17 7/8 x 24 7/8 (454 x 632)

030-036 — 19 7/8 x 24 7/8 (504 x 632)

042-070 — 27 7/8 x 29 7/8 (708 x 759)

WARNING

Hazardous Chemicals!

Cleaning agents can be either acidic or highly alkaline.

Handle chemical carefully. Proper handling should include goggles or face shield, chemical resistant gloves, boots, apron or suit as required. For personal safety, refer to the cleaning agent manufacturers Materials Safety Data Sheet and follow all recommended safe handling practices. Failure to follow all safety instructions could result in death or serious injury.

Table 58. Water quality

Scaling Amount

Calcium and magnesium (total hardness) Less than 350 ppm

Corrosion pH 7-9.5

Hydrogen Sulfide Less than 1 ppm

Sulfates Less than 25 ppm

Chlorides Less than 125 ppm

Carbon Dioxide Less than 75 ppm

Total dissolved solids (TDS) Less than 1000 ppm

Biological Growth

Iron Bacteria Low

Erosion

Suspended Solids Low

VAV-SVN01E-EN 55

Maintenance

Periodic maintenance of the VariTrane product is minimal, but necessary for efficient operation. Routine mainte-nance consists of inspecting/replacing the air filters of the fan-powered terminals.

Motors

Both the PSC (permanent split capaci-tor) and the ECM (Electrically Commu-tated Motor) require no lubrication during its normal life of operation.

Fan Wheel:

Periodically, the fan wheel should be inspected for dirt or debris and cleaned as necessary.

Filter

The filter on fan-powered terminals will need to be inspected/replaced routinely depending on the environmental conditions of the plenum.

Water Coil

Water coils should be inspected and the fins should be cleaned periodically.

Water coils have been provided with an access panel as standard to assist with inspection and cleaning.

Fan Motor Replacement

Standard height fan-powered series and parallel fan motors are replaceable through the filter opening and the standard sliding side access panel. To access the fan motor, the fan housing must be detached by removing the mounting bolts that hold the housing to the fan board. Removing the entire housing allows the fan motor, fan housing, and fan wheel to be re-aligned on a workbench or floor and prevent any possible fan wheel rubbing that may occur. Removing the housing will provide access to the motor shaft set screw that holds the fan wheel to the motor shaft.

The low-height fan assembly was designed with an inlet ring that assists with removal of the fan motor. To access the fan motor assembly, the bottom panel must be removed. The inlet ring is held in place by six bolts and three motor mount bolts. Remove these bolts and the motor and fan wheel will come out of the fan housing.

Figure 27 – Standard Motor Removal

WARNINGWARNING

WARNINGWARNING

Rotating Components!

Disconnect all electric power, including remote disconnects before servicing.

Follow proper lockout/tagout proce-dures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

Hazardous Voltage w/Capacitors!

Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. Verify with an appropriate voltmeter that all capacitors have discharged. Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury.

Figure 28 – Low-Height Motor Removal