Maintenance Instructions
Contents
1. C PA MAINTENANCE INSTRUCTIONS NOTE Failure to follow recommended maintenance procedures could void unit warranties Interior Sanitization The interior of the unit should be cleaned and sanitized periodically The frequency of cleaning will be dependent upon the application and the HACCP procedures outlined forthe airhandling unit It is extremely critical that the chemicals used to clean the unit are compatible with the interior materials and components It is recommended the supplier of cleaners and sanitizers for the plant be consulted so they can make recommendations on proper cleaning procedures and processes forthe unit When cleaning the unit 1 2 NO 9 Make sure the unit is locked and tagged out per plant procedures Cleaning personnel should make sure to have proper protective clothing as per their standard operating procedures 3 Make sure all of the filters have been removed from the unit 4 5 Protect any control devices inside the unit with waterproof covering If the unit is supplied with UVC lights protect both the light and the fixture from the cleaning process Make sure that all of the drain connections are open Do not aggressively spray wash the motor bearings Aggressive washing can damage the seal and wash out the grease Thiscan cause premature failure of the bearing The coils can be cleaned however do not spray with high pressure system especially at an angle toward the fins Th2. Check all drain traps to make sure that they are not plugged and have an adequate waterseal Make sure that the otherdrain pansdo not have standing water in them 4 Checkall door gasketing yearly to make sure there isan airtight seal EVAPCO Inc 215 14 Steet NE P O Box 88 Medford MN 55049 2 1 1211 Phone 507 446 8005 Fax 507 446 8239
3. AN AMMONIA LEAK SIRICT SERVICE AND MAINTENANCE SCHEDULES MUST BE FOLLOWED AND COMPLETE SERVICE REC ORDS KEPT UVC Lights Optional feature 1 CAUTION NEVER EXPOSE EYES OR SKIN TO UVC LIGHT ALWAYS TURN POWER OFF OR WEAR GLOVES FACE SHIELDS AND COVER ANY EXPOSED SKIN BEFORE SERVICING THE UNIT 2 CAUTION IMPROPER SERVICE AND MAINTENANCE CAN CAUSE ARE ELECTRIC AL SHOC K OR OTHER CONDITIONS THAT MAY CAUSE PERSONAL INJ URY OR PROPERTY DAMAGE 3 The bulbs should be replaced every 12 18 monthsand should need no maintenance between replacements Carefully remove the old bulb s and check all wiring and connectionsto the bulbs Carefully inspect the watertight assembly and replace if necessary 4 Test all circuits Leave the unit close the accessdoor and then tum the lightson A blue hue will glow from the light indicating the fixture is working Remember only view the lights through the service door window or while wearing the protective gear as described above 5 Mark your preventative maintenance calendarto replace the bulbsone year from the replacement date 6 Check local codes for proper disposal of the used bulbs Desic cant Dehumidific ation Optional feature 6 1 CAUTION The desiccant wheel is constucted of a fragile composite material DO NOTclean with water chemicals solvents or high pressure sprays 2 See the separate section in the maintenance manual for proper cleaning and maintenance of the desicca
4. Dolium R Greasing procedure Clean the grease fitting orthe area around the hole if equipped with slotted grease screws If motorhasa purge plug remove it Apply grease gun fitting Too much grease orinjecting grease too quickly can cause premature bearing failure Slowly apply the recommended amount of grease taking 1 minute or more to apply Operate motor for 20 minutes the reinstall purge plug if previously removed Caution Mixing dissimilar grease isnot recommended Amount of Grease to Add Amount of Grease to Motor Horsepower Add Weight in Volume in Ounces Teaspoons 2 10 0 61 3 9 40 0 81 5 2 50 and above 2 12 13 4 5 If the unit is supplied with spring isolation check spring bolts nuts for tightness Also check the flexible duct for wear Elec tric al Connections The control system for the unit should be checked at least twice a year for proper operation of the system Also check all terminals to ensure they are tight It is suggested that the units be checked in the fall prior to the heating season and in the spring prior to the summer cooling season Make sure that all settings are per the operation manual Smoke Detector Optional Feature IMPORTANT The smoke detector must be tested and maintained regulary following NFPA 72 requirements The detector should be cleaned and tested at least once a year Detailed information on maintenance and service is contained within th
5. an motor 8 Make note in the maintenance schedule for the unit that the final filters have been changed 9 Check filter gauge forproperoperation Recalibrate if necessary Absolute HEPA Final Filters The absolute HEPA filters are a cartridge type filter each held with four holding clips The filter media isa fine fiber glass materal The absolute HEPA filters should be changed when the reading on the final filter gauge indicates approximately 2 0 pressure drop across the filters The pressure drops should be read with the unit operating all service doors closed and the prefilters in their clean position Typically the final filters should last 6 months to 15 months depending upon the cleanliness of the application the frequency of prefilter changes and if the unit cleanup cycle is operated properly The filter gauge will ensure the final filters have reached their full life and are not changed prematurely The filters are in stock at EVAPCO please call 507 446 8005 for immediate shipment of filters Use the following procedure to change the filters 1 Stop the fan motorand lockout using disconnect switch 2 Remove the fully loaded final filters NOTE Maintenance personnel may want to use protective clothing and facemasks while changing Be careful not to dislodge any of the particles collected in the filter 3 Inspect the final filter frame gasketing and the retaining clips 4 Check the caulking seal between th
6. e final filter frames If any cracks are observed caulk with a USDA FDA sealant 5 Install the new absolute HEPA final filters The pleats should be in the vertical position 6 Clean and sanitize the final filter section 7 Start the fan motor 8 Make note in the maintenance schedule for the unit that the final filters have been changed 9 Check filter gauge forproperoperation Recalibrate if necessary Blower Motor and Drive Assembly 1 Every 6 months the fastening bolts for the blower motor and drive should be checked for tightness Also check the bearing set screws and the blower hub set screws Check alignment of the sheaves 2 A periodic maintenance schedule should be set up for checking the belts At minimum the belts should be checked every 6 to 9 months for wear and proper tightness and alignment 3 The blower bearings should be lubricated per the lubrication instructions and schedule in the service manual 4 Motors that do not have re grease capability are factory lubricated for the nomal life of the bearings For motors with re grease capability they should be lubricated at these intervals Motor Horsepower Rated Speed RPM 3600 1800 1200 900 2 5500 12000 18000 22000 10 3600 9500 15000 18000 40 2200 7400 12000 15000 50 and above 2200 3500 7400 10500 Baldor motors should normally be greased with Exxon Mobil Polyrex EM grease and U S motors either a Chevron SRI 2 ora Shell
7. e service manual for this unit WARNING WITHOUTPROPER SERVICE AND MAINTENANCE THE SMOKE DETECTOR COULD INMATE FALSE ALARMS OR FAIL TO FUNCTION PROPERLY IN THE CASE OF A ARE SIRICT SERVICE AND MAINTENANCE SCHEDULES MUST BE FOLLOWED AND COMPLETE SERVICE REC ORDS KEPT Surge Drum Pressure Relief Valves Optional Feature These tamperresstant pressure relief valves are accurately factory set and do not require any field adjustments whatsoever They are intended for one time over pressure operation and should be replaced immediately after discharging because setting or seat tightness may be altered Every sx months relief valves shall be visually inspected for cormoson or accumulation of scale and for leaks Normally pressure relief valves should be removed and replaced with new valvesat least every five years Even when simply replacing an existing valve a review of requirements per current local and national code is advisable Valves should not be removed unless system has been evacuated to zero pressure NOTE See service manual for more detailed information Ammonia Detector Optional Feature For proper operation it is essential that the test and calibration schedule be adhered to The supplier recommends the following maintenance schedule 1 Response test once per month Expose sensor to ammonia water solution to verify proper sensor response and alam functions Test more frequently in highly Critical applications 2 Calibration s
8. hould be performed with certified calibration gas every six months Alltests and calibrations must be logged Sensor Life These electrochemical cells are extremely reliable but several things can cause the cell chemicals to become depleted including 1 A period of time 2 Exposure to high temperatures 3 Exposure to varying concentrations of the target gas 4 Exposure to high moisture forextended periods without proper sensor enclosure When the cell becomes depleted the unit will give no indication of failure other than that the sensor will not respond For this reason it is absolutely essential that these units be exercised with a gas sample on a regularand timely basis Typical sensor life in a refrigerated area will be 18 monthsto 2 yearsormore Typical life in a non refrigerated area will be 12 months or less Exposure to high levels of ammonia will shorten these times In addition to timely response checks a preventative maintenance program of penodic cell replacement should be implemented When the cell becomes depleted a replacement cell can be obtained from Manning Systems Simply unplug the ribbon cable from the pins labeled Sensor pull the old cell from the spring clip discard the old celland replace it with a new one The sensor should be calibrated aftera 24 hour warm up period WARNING VWAITHOUT PROPER SERVICE AND MAINTENANCE THE AMMONIA DETECTOR COULD INMATE FALSE ALARMS OR FAIL TO FUNCTION PROPERLY IN THE CASE OF
9. ial with an optional synthetic filter The 95 filters should be changed when the reading on the final filter gauge indicates approximately 1 1 to 1 2 pressure drop across the filters The pressure drops should be read with the unit operating all service doorsclosed and new prefiltersin place Typically the final filters should last 6 months to 15 months depending upon the Cleanliness of the application the frequency of prefilter changes and if the unit cleanup cycle is operated propery The filter gauge will ensure the final filters have 2 reached their full life and are not changed prematurely The filters are in stock at EVAPCO please call 507 446 8005 for immediate shipment of filters Use the following procedure to change the filters 1 Stop the fan motorand lockout using disconnect switch 2 Remove the fully loaded final filters NOTE Maintenance personnel may want to use protective clothing and facemasks while changing Be careful not to dislodge any of the particles collected in the filter 3 Inspect the final filter frame gasketing in some applications the gasketing is on the filterand not the frame and the retaining clips 4 Check the caulking seal between the final filter frames If any cracks are observed caulk with a USDA FDA approved sealant 5 Install the new 95 final filters The pleats should be in the vertical position if possible 6 Clean and sanitize the final filter section 7 Start the f
10. is can bend the leading edge of the fins over If the coil has aluminum fins do not use caustic cleaners Do not aggressively spray the gasketing on the filters This can damage the gasketing 10 Do not aggressively spray the caulked seams in the unit This can damage or dislodge the sealing caulk Priorto putting the unit back in operation 1 DU Make sure the interior of unit is as dry as possible Operating before the unit is dry can cause water to be aibome and damage the electrical components or get the filters wet and damage them Make sure any drain caps that have been removed for cleaning are replaced and sealed Remove all protective coverings used during the cleaning process Check all the caulked seams in the unit for integrity Caulking is a routine maintenance item Check the gasketing on the filterframes Replace if necessary Replace all filters and remove all protective material from interior components 1 Pre filter Service The prefilters in the CPA unit are a pleated synthetic media filter with a moisture resistant frame each held in place with two holding clips The frequency of changing of the prefilters is determined by the cleanliness of the air passing through them and the proper operation of the unit during the cleanup cycle Most prefilter systems are changed on a preventative maintenance schedule and not purely by the appearance of the filter Visible dirt on the surface isnot a true indication of fu
11. ll loading of the filter However it can be an initial indicator If the CPA unit is supplied with a filter gauge the filters should be changed ata 0 8 to 1 0 w g reading Typical life of the filter should be anywhere from 30 days to 90 days depending upon the application and operation of the unit The prefilters are in stock at EVAPCO please call 507 446 8005 for immediate shipment of prefilters Use the following procedure to change the prefilters 1 Stop the fan motorand lockout using the disconnect switch 2 Remove each filter from their individual holding frame 3 Inspect the filter frame gasketing caulking between the frames and holding clips and replace if necessary 4 Clean and sanitize the prefilter section 5 Install the new prefilters The prefilters should have the pleats in the vertical position if possible 6 Start the fan motor 7 It is suggested that the prefilters be checked after approximately 8 hours of operation to ensure that they have been installed propeny 8 Make note in the maintenance schedule for the unit Final Filter Service CPA units can be supplied with two types of final filters 95 and HEPA filters These filters are typically located at the discharge of the unit The following is the servicing procedures forthe two types of filters 95 Fina Filters The 95 filters are a cartridge type filter each held with four spring holding clips The filter media isa fine fiberglass mater
12. nt wheel and system VFD Drive Systems Optional feature 1 The control panel enclosing the VFD may contain an ambient air cooling ventilation system This cooling system is used to control the interior control panel temperatures for the VFD The cooling system contains a filter which must be penodically cleaned It isrecommended it be cleaned as least as often as the pre filters in the unit and more frequently if the atmosphere around the unit is very dirty and dusty Failure to keep the panel cooling filter clean can Cause reduced cooling air flow to the contol panel This can result in overheating of the VFD which can then cause faults and or failure of the drive and possible damage to the unit motor Unit Motor Removal Rail option Some units include motor removal rail trolley system to facilitate easier and safer removal of the unit motor Please refer to the trolley installation instruc tions for proper mounting of the trolley Priorto every use make sure the fasteners and hardware are tight and aligned Do not swing the motor when on the trolley since this may stress the beam ortrolley and cause an unsafe condition Miscellaneous Items 1 Check the operation of the dampers every time the electrical controls are checked Make sure that all of the linkage operates freely and the dampers function corectly 2 Check the seal between the sections on the units Make sure the section split seals remain water and airtight 3
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