¶ OPERATION AND MAINTENANCE
The following prescribed maintenance and service intervals for individual parts of the unit must be carried out to maintain the validity of the warranty from the manufacturer MANDÍK, a.s., and for trouble-free and safe operation of the unit.
These intervals are intended for standard units under normal operating conditions. For units operated differently (24-hour operation, higher operating temperatures, higher dust levels in the surrounding air, etc.), the maintenance and service intervals must be shortened by at least one level. It always depends on the specific operating conditions, according to which the intervals are determined during commissioning, training, and handover of the unit.
All performed service interventions, maintenance, and inspections must always be recorded in the operational log of the unit. The obligation to establish and maintain the operational log lies with the person who puts the unit into operation. The operator of the unit makes entries about individual events.
SAFETY DURING MAINTENANCE:
• WARNING: ALL WORK, MAINTENANCE, AND INTERVENTIONS ON THE EQUIPMENT MAY ONLY BE PERFORMED BY QUALIFIED PERSONS WITH APPROPRIATE AUTHORIZATIONS (E.G., GAS INSTALLATION, ELECTRICAL INSTALLATION, ETC.)!
• WARNING: SERVICE WORK AND MAINTENANCE ON THE EQUIPMENT MAY ONLY BE PERFORMED WHEN THE EQUIPMENT IS TURNED OFF (IT MUST BE SECURED AGAINST UNINTENDED STARTUP OR STARTUP BY ANOTHER PERSON)!
• WARNING: BEFORE ENTERING THE EQUIPMENT, ALL ROTATING PARTS (FANS, ROTATING HEAT EXCHANGERS, ...) MUST BE IN A RESTING STATE!
• WARNING: HEAT EXCHANGERS, PARTS OF THE HYDRAULIC SYSTEM, AND PARTS OF THE EVAPORATOR COOLING CIRCUIT MUST BE COOLED TO AMBIENT TEMPERATURE; MAXIMUM SURFACE TEMPERATURE IS +40°C!
• WARNING: THE PRESSURE OF THE PRESSURE SYSTEMS IS EQUALIZED TO AMBIENT PRESSURE!
¶ OPERATION AND MAINTENANCE OF THE UNIT IN GENERAL
All persons performing maintenance on air conditioning units must be familiar with the contents of the maintenance instructions and follow the recommendations provided therein. These instructions are only a supplementary source of information and presume knowledge of the installation and operational regulations for air conditioning units from MANDÍK, a.s. series M/M+, P/P+, S/S+, T/T+, CPV, and CPX, as well as compliance with all requirements contained therein. The manufacturer assumes no responsibility for any damages resulting from non-compliance with installation and operational regulations and these instructions.
Air conditioning units are machines for transporting and conditioning air, which require regular maintenance and cleaning. Depending on the extent and purpose of the ventilation equipment they are part of, as well as the composition and equipment of the air conditioning unit itself, we recommend that the operator prepare a local regulation for operation and maintenance that respects the requirements of installation and operational regulations and further the maintenance instructions for air conditioning units from MANDÍK, a.s. series M/M+, P/P+, S/S+, T/T+, CPV, and CPX.
All time intervals mentioned in the following text for maintenance are only indicative and valid for air containing normal amounts of pollutants. These time intervals may be extended or shortened depending on local operating conditions, the nature of the equipment, and the pollution of the transported air. These intervals also do not absolve the operator from the obligation to ensure the flawless and safe operation of the air conditioning unit daily.
All elements designed for withdrawal, opening, or easy disassembly must be positioned to allow for the most thorough cleaning of the unit's interior. Coarse dirt should be removed with a vacuum cleaner, and a damp cloth should be used if necessary. For greasy dirt, neutral cleaning agents should be used, and then the surface should be wiped again with a damp cloth. Any damage to painted surfaces or signs of corrosion must be treated and repaired with an appropriate coating. Moving parts (hinges, handles, etc.) should be lubricated as needed. All access doors must be properly seated and checked to ensure they open freely. Depending on the conditions of the unit's placement, it may be necessary to adjust the doors within the adjusting tolerances on the hinge and handle screws. The correct seating of the doors on the sealing surfaces should be checked. Door seals must be inspected; if there is any leakage, they must be repaired or replaced.
¶ FAN CHAMBER
Before starting any interventions or work in the chamber, it is necessary to wait for the fan wheel to come to a complete stop. It is also essential to prevent unintended startup or accidental operation of the fan by another person! A safety switch located on the front or side of the unit (depending on the specific design of the unit) is intended for this purpose.
In the fan, we check the cleanliness of the free fan wheel; any coarse dust should be removed with a vacuum cleaner, and fine dust wiped away with a damp cloth.
Maintaining the fan wheel in a clean state is crucial, especially for ensuring the best possible balance. Any damage to painted surfaces or signs of corrosion must be treated and repaired with an appropriate coating.
Regularly check for any imbalance (vibration), the attachment of the fan wheel to the hub, and the hub to the motor shaft. Additionally, check the gap width between the free fan wheel and the suction inlet of the fan, and tighten all screw connections on the motor and fan assembly. For the electric motor, check for vibrations, bearing noise, possible excessive heating, tighten the terminals in the terminal box, and ensure the integrity of the electrical connection to the chamber's frame.
During maintenance, we measure the motor current, check the voltage, and phase symmetry. Any surface damage should be repaired. Check the proper attachment of the electric motor to the base and all screw connections on the fan assembly's base. We also verify the functionality of the rubber vibration dampers under the assembly and their anchoring. Periodic checks also include verifying the tightness and integrity of the flexible sleeve at the fan's suction and cleaning it.
If the fan is equipped with a safety differential manometer, we check its correct operation by performing a test with appropriate overpressure in the chamber.
¶ FILTER CHAMBER
Dust settled on the filter insert can cause allergic reactions on the skin, mucous membranes, and eyes, or respiratory difficulties. Therefore, avoid contact with trapped dust. When maintaining and replacing filter inserts, protective clothing and, if necessary, protective equipment (such as a respirator) must be used!
In the filter chamber, we check the cleanliness of the chamber, removing any coarse dust with a vacuum cleaner and wiping fine dust with a damp cloth. We also check for clogging and the tightness of the entire filter insert. When replacing filters, it is essential to prevent contamination of the chambers or new filter inserts with trapped dust.
¶ Pocket and Frame Filters
Depending on the filtration class of the filters used and the interval for their replacement, it is necessary to always timely supplement the stock with at least one set of spare filters while ensuring that their prescribed maximum storage period is not exceeded. We recommend establishing a filter replacement interval based on observations made during the trial operation of the unit. This interval may be shorter or longer than the regular maintenance interval, depending on local conditions. However, the maximum allowable end pressure drop for the type of filter insert used must not be exceeded, and the time interval between individual replacements must not exceed 12 months (applicable for the first stage of filtration); for the second and subsequent stages of filtration, as well as filters for drainage parts of the units, this period may be determined individually, but should not exceed 24 months. Typically, all filters in the entire filter insert are replaced simultaneously; the replacement of individual filters is only permissible in the case of their damage.
¶ Activated Carbon Filters
In operations where health-safe odors are separated by activated carbon filters, the functionality of the filter can be checked sensorially by olfactory perception. In cases where substances without odor, toxic, and other health-hazardous substances are separated, the saturation of activated carbon and the remaining lifespan of the filters can only be determined through laboratory testing, which can be conducted by the filter cartridge manufacturer. Based on this testing, the replacement interval for activated carbon cartridges can then be determined. However, when determining the replacement interval, it is always necessary to consider the properties and nature of the separated substances, especially regarding their potential health hazards or other dangers.
Recommended end pressure losses for the filters are listed in Appendix F.
Setting a different switching value for the pressure difference is possible by manually adjusting the value on the switching manostat of the inlet/outlet filter. The manostats are located under the filters on the side of the chamber for CPV or in the control panel for CPX, see the following image.
A: INLET FILTER
B: INLET MANOMETER
Recommended final pressure losses of the filters:
• Values are listed in the relevant technical specification for the unit, according to the selected filtration class and type of filter
¶ END PANELS WITH FLAP, FLAP CHAMBERS, AND DAMPING INSERTS
The leaves of the open flap must be secured against spontaneous or accidental closing. Never stick limbs between the leaves of the open flap; there is a danger of serious injury!
We check for contamination, any damage, the mobility of the flap leaves, and especially the correctness of the flap closure. Any dust deposits are removed with a vacuum cleaner, and the surface of the flap leaves can then be cleaned with a damp cloth. The plastic gears of the flaps are made from a material that does not require additional lubrication. For flaps with lever mechanisms, lubricate the necessary points of the lever transmission with lubricant spray. If there is a flexible sleeve following the flap, we check its tightness and integrity, and if necessary, we clean it.
¶ WATER AND STEAM HEATING CHAMBER, WATER COOLING CHAMBER
The surface temperature of the heater and medium connections during operation may exceed the safe touch temperature of 60°C. Before starting any interventions or work in the chamber, it is necessary to wait for the heat exchanger and connections to sufficiently cool down.
When filling, draining, and venting the heat exchanger, avoid contact between unprotected skin and the heat-carrying medium. When using additives or complete ready mixtures in heating or cooling systems, be sure to follow the manufacturer's information regarding the use and handling of these substances.
In the heat exchangers, we check for contamination, tightness, and any damage. Contamination is removed by blowing air, steam, or using a hot water pressure cleaner against the airflow. In every case, it is essential to ensure that the fins of the heat exchanger do not get deformed; therefore, high-pressure devices, whether water or air, should not be used for cleaning.
We regularly check the tightness of the connecting fittings and the functionality of the venting valves. Regardless of the established maintenance intervals, always before the cold season of the year, we check the functionality of the frost protection system and, if necessary, check the concentration of the antifreeze mixture. For chillers before the winter period, and for all heat exchangers before extended downtime (if not filled with an antifreeze mixture with sufficient concentration), we drain the medium. The mere draining of the medium does not guarantee the removal of all liquid from the heat exchanger; it is absolutely necessary to additionally blow the heat exchanger with compressed air!
For chillers, we also check the condition and function of the condensate drain trays, the drainability from the tray, and the condition and function of the siphon; if necessary, we clean and refill water. Before winter, we check the functionality of the measures against freezing at the condensate drains (if they are in operation during the winter and there is a risk of freezing). Furthermore, we check for the presence of deposits, the condition, and cleanliness of the droplet eliminator; if necessary, we pull it out and clean it.
¶ CHAMBER WITH PLATE HEAT RECOVER
The leaves of the open flap must be secured against spontaneous or accidental closing. Never stick limbs between the leaves of the open flap; there is a danger of serious injury!
We check the condition and contamination of the heat recuperator, the functionality of the flaps, the condensate drains, and the droplet eliminator.
Contamination of the recuperator is removed by blowing air, steam, or using a hot water pressure cleaner. In every case, it is essential to ensure that the fins of the heat exchanger do not get deformed.
We check for contamination, any damage, and the mobility of the flap leaves. Any dust deposits are removed with a vacuum cleaner. The surface of the flap leaves can then be cleaned with a damp cloth. The plastic gears of the flaps are made from a material that does not require additional lubrication. For flaps with lever mechanisms, lubricate the necessary points of the lever transmission with lubricant spray.
We check the condition and functionality of the condensate drain trays, the drainability from the tray, and the condition and functionality of the siphon; if necessary, we clean and refill water. Before winter, we check the functionality of the measures against freezing at the condensate drains (if there is a risk of freezing).
Furthermore, we check for the presence of deposits, the condition, and cleanliness of the droplet eliminator; if necessary, we pull it out and clean it.