Application: Man Hours 4
This applies to self-contained heating and cooling
units containing a complete cooling system and heating unit (gas or oil burner).
These are normally installed on rooftops, but can be in other locations. They
are also referred to as climate changers, roof packs, etc.
Special Instructions:
1. Schedule shutdowns with operating personnel, as needed.
2. Review manufacturer's instructions.
3. Review the Procedure for "Controlling Hazardous Energy
Sources."
4. Deenergize, lock and tag electrical circuits.
5. Comply with the latest provisions of the Clean Air Act and Environmental
Protection Agency (EPA) regulations as they apply to protection of
stratospheric ozone.
6. No intentional venting of refrigerants is permitted. During the servicing,
maintenance, and repair of refrigeration equipment, the refrigerant must be
recovered.
7. Whenever refrigerant is added or removed from equipment, record the
quantities on the appropriate forms.
8. Recover, recycle, or reclaim the refrigerant as appropriate.
9. If disposal of the equipment item is required, follow regulations concerning
removal of refrigerants and disposal.
10. If materials containing refrigerants are discarded, comply with EPA
regulations as applicable.
11. Refrigerant oils to be removed for disposal must be analyzed for hazardous
waste and handled accordingly.
12. Closely follow all safety procedures described in the
Material Safety Data Sheet (MSDS) for the refrigerant and all labels on
refrigerant containers.
1. ___ Remove debris from air screen and clean underneath unit.
2. ___ Inspect gaskets. Look for leaks between unit and
structure, caulk as necessary.
3. ___ Clean condenser, cooling coil fins, and fans.
4. ___ Remove dirt or dust from all interior parts.
5. ___ Replace filter.
6. ___ Inspect and adjust damper.
7. ___ Lubricate motor and fan bearings.
8. ___ Check fan RPM to design specifications.
9. ___ Check bearing collar set screws on fan shaft to make
sure they are tight.
10.___ Check dampers for dirt accumulations. Check felt. Repair or replace as
necessary.
11.___ Check damper motors and linkage for proper operation.
12.___ Lubricate mechanical connections of dampers sparingly.
13.___ Clean coils by brushing, blowing, vacuuming or pressure
washing.
14.___ Check coils for leaking, tightness of fittings:
___ a. Check for refrigerant leaks using a halogen
detector or similar testing device. If leaks are not able to be
stopped or corrected, report leak status to supervisor. Consult the
Material Safety Data Sheets (MSDS) for disposal requirements.
Reclaimed and recycled CFCs are exempt from hazardous waste
regulations (Consult 40 CFR Part 261).
___ b. Check refrigerant levels and recharge if needed.
15.___ Use fin comb to straighten coil fins.
16.___ Flush and clean condensate pans and drains.
17.___ Check belts for wear, adjust tension or alignment and
replace belts when necessary. Multi-belt drives should be
replaced with matched sets.
18.___ Check rigid couplings for alignment on direct drives and
for tightness of assembly. Check flexible couplings for
alignment and wear.
19.___ Check electrical connections for tightness.
20.___ Check mounting for tightness.
21.___ Check for corrosion.
22.___ Check mounting bolts and tighten if needed.
23.___ Check and adjust, or replace if necessary, vibration eliminators.
24. Compressor.
___ a. Check compressor oil level.
___ b. Run machine, check action of controls, relays, switches,
etc., to see that:
(1). compressor(s) run at proper settings.
(2). reheat coils activate properly.
(3). crankcase heater is operating properly.
(4). suction and discharge pressures are proper.
(5). discharge air temperature is set properly.
25. Heating Unit.
a. Gas and/or oil fired (if equipped).
(1).___ Check burner for flashback and tight shutoff of fuel.
(2).___ Check operation of controls. Clean and adjust if necessary.
(3).___ Clean burner, chamber, thermocouple and control. (Use a high
suction vacuum and/or brush.) Check combustion chamber for
cracks, holes, or other defects.
(4).___ Adjust pilot or electric ignition device.
(5).___ Inspect vent and damper operation.
(6).___ Operate unit and adjust burner.
(7).___ Check operation of safety pilot, gas shutoff valve, and other
burner safety devices.
(8).___ Check temperature differential and controls.
(9).___ Check frame of unit with ohmmeter for proper electric ground.
(10).___ Replace covers (if any) and clean area.
b. Electrical (if equipped).
(1).___ Visually inspect for broken parts, contact arcing or any
evidence of overheating. Inspect all wiring for deterioration.
(2).___ Check name plate for current rating and controller
manufacturer's recommended heater size. (Heater size
shall not be changed without the regional design
engineer's approval.)
(3).___ Check line and load connections and heater mounting screws for
tightness.
Tools and Materials:
1. Standard Tool Kit
Plus Refrigeration - gauges
Leak detector-electronic or halogen
Pocket thermometer
Clamp on meter (volt - ohm - amp meter)
Flaring tool
Tubing cutters
Packing kit and packing
Crescent wrenches to 14"
2. Tachometer
3. Grease gun and oiler
4. Pressure washer
5. Vacuum
6. Fin comb
7. Cleaning tools, approved refrigerant, and materials. Consult the MSDS for
hazardous ingredients and proper personal protective equipment.
8. Safety goggles and gloves.
9. CO2 analyzer
10. Self sealing quick disconnect refrigerant hose fittings
11. Refrigerant recovery/recycle unit
12. EPA/DOT approved refrigerant storage tanks.
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