OPERATION AND MAINTENANCE MANUAL

KLINIK & PEJABAT TAWAU ACMV O&M

LIST OF CONTENTS

SECTION TITLE

1. System Overview
(A) Air Conditioning System
(B) Air-conditioning System — Split Air-cooled.
(C) Mechanical Ventilation System

2. Operation Procedure
(A) Air Conditioning System
(B) Air-conditioning System — Split Air-cooled.
(C) Mechanical Ventilation System

3. Operator's Knowledge

4. Maintenance
(A) Centrifugal Liquid Chillers
- Daily Maintenance
- Weekly Maintenance
- Annually Maintenance

(B) Chilled Water and Condensing Water Pumps

- Monthly Maintenance

(C) Cooling Towers

- Daily Maintenance
- Quarterly Maintenance

(D) Air Handling Units

- Quarterly Maintenance

(E) Chilled Water Fan Coil Units

- Quarterly Maintenance

(F) Switchboards, Control Panels

- Annually Maintenance

(G) Air-cooled Split Air-conditioning units

- Quarterly Maintenance

(H) Exhaust Fans

- Yearly Maintenance
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

5. Water Treatment
(A) Condensing Water
- Daily dosage
- Monthly water sample analysis

(B) Chilled Water

- Annually water sample analysis

6. List of Equipments (Appendix)

Appendix 1: York Chiller
Appendix 2: York Air Handling Units
Appendix 3: Ebsray Chilled Water Pumpsets
Appendix 4: Ebsray Condensing Pumpsets
Appendix 5: Truwater Cooling Tower
Appendix 6: Kruger Fans (Exhaust Air Fans)
Appendix 7: York Fan Coil Units

7. Catalogue & Operation Manual Of Main Equipment

(a) York Screw Chiller (YEWS)
(b) York Air Handling Unit (YSM)
(c) York Ducted Fan Coil Unit (YSD)
(d) York Ducted Fan Coil Unit (YCF)
(e) York Ducted Fan Coil Unit (DCP)
(f) York Ducted Fan Coil Unit (CRBH)
(g) York Air-Cooled Wall Mounted Split Unit
(h) Truwater Cooling Tower
(i) Ebsray End Suction Pumps
(j) Kruger Fans
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

SECTION 1

System
Overview
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

System Overview

1. SYSTEM OVERVIEW

A. AIR CONDITIONING SYSTEM

1. The Air-Conditioning System comprises of the following equipments: -

( i) 4 units of "York" Centrifugal Liquid Chiller.

(ii) 10 units "York" Modular Air Handling Units (AHU).

(iii) 20 units "York" Ceiling Concealed chilled-water Fan Coil Unit. (FCU).

(iv) 4 sets of "Ebsray" Chilled water pump.

(v) 4 sets of “Ebsray" Condensing water pump.

(vi) 4 sets of "Truwater" Cooling Tower.

(vii) 1 set of chemical dosing pump.

(vii) 1 set of Chiller's Main Switch Board (MSB).

(viii) 1 set of Chilled Water Piping from the Chillers to AHU(s) and FCU(s).

(ix) 1 set of Condensing Piping from the Chillers to Cooling Towers.

(x) Ducting for AHU(s) and FCU(s)

OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

System Overview
2 Chillers Brief Description

a) Screw Chillers are located at the M&E Building Chiller Plant Room, are controlled by a
Microcomputer Control Center that monitors its operation. It can be programmed to suit job
specifications. In operation, water flows through the evaporator, where boiling refrigerant absorbs
heat from the water. The chilled water is then piped to Air Handling units AHU(s) and Fan Coil
units FCU(s). The chilled water flows through the finned coil of the AHU(s) and FCU(s),
absorbing heat from the air. The warmed water is then returned to the chiller to complete the
chilled water circuit. The refrigerant vapor, which is produced by the boiling action in the
evaporator, flows to the compressor where the rotating impeller increases its pressure and
temperature and discharges it into the condenser. Water flowing through the condenser tubes
absorbs heat from the refrigerant vapor, causing it to condense. The condenser water is supplied
to the chiller from the cooling tower. The condensed refrigerant drains from the condenser into
the liquid return line, where the variable orifice meters the flow of liquid refrigerant to the
evaporator to complete the refrigerant circuit.

b) The oil heater operation is controlled by the Microcomputer Control Center. It is turned on and
off to maintain the oil temperature at 10 deg C (50 deg F).

c) The chilled water produced by the chillers is being circulated by Chilled Water Pumps to all Air
Handling Units (AHU) and Fan Coil Units (FCU) in the main building.

d) The Condenser water from the Chillers is being cooled by Condensing Water Pump circulating to
3 sets of Cooling Tower.

e) AHU(s) and FCU(s), completed with cooling coil; fan motor, valves, strainer, thermostat, filter,
control panel (where necessary) and control wiring are installed at various locations of the
building to cool different areas of the building.

f) The ducting from AHU(s) and FCU(s) is installed to distribute the cooled Air from AHU(s) and
FCU(s) to cool the specific areas through Square Diffusers, Round Diffusers and Linear
Diffusers. The cool air supplying to the area is returned to AHU(s) and FCU(s) through Return
Air-Grilles. Two systems of return air are being implemented depending on the design of the Air-
conditioning system. There are ceiling return and ducted return.

g) All AHU(s) rooms are equipped with sound proof. The wall of the AHU(s)'s rooms is insulated
with Rock Wool of 50mmX 40kg/m3 covered by the 3mm perforated sheet.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

System Overview

h) To achieve acceptable quality of condensing water, a treatment program should be implemented.

Sample of water will be taken and tested monthly. Based on the result, the quantity of chemicals
will be mixed and is injected into the condensing water system by chemical dosing pump. These
chemicals are to control the following parameters to achieve the desired quality of condensing
water.

PARAMETERS LIMITS MEANS of ADJUSTMENT

pH 7.2 to 8.5 Bleed-off to control
M-alkalinity 300max Bleed-off to control
(ppm CaCO3)
Total Hardness 400max Bleed-off to control
(ppm CaCO3)
T.D.S. 500Max Bleed-off to control
Molybedate (Mo04) 0.5- 1 ppm Add CL CL-4810-+-control
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

System Overview

B. AIR-CONDITIONING SYSTEM — Split Air-cooled Air-conditioning unit

There is certain areas in the mall that are cooled by Air-cooled Split Air-conditioning units. The
Air-cooled Split Air-conditioning unit consists of a fan coil unit and condensing unit. The Fan
units installed are Wall mounted type and all are wireless control (Remote).

C. MECHANICAL VENTILATION SYSTEM

All mechanical rooms in the M&E building are installed with suitable fresh air fans and exhaust
Fans. All toilets, washrooms and specific rooms are installed with suitable exhaust fan. Ducting is
installed for all these Exhaust fans and fresh air Fans to supply and extract air from the rooms or
areas.

Refer to Equipment schedule for list of fans and their details specification. These fans were
installed as per As-Built Drawing.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

SECTION 2

Operation
Procedure
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

Operation Procedure

2. OPERATION PROCEDURE

A. AIR CONDITIONING SYSTEM

a) Check power supply to main Air-Con. Switchboard in the Air-Con Plant Room and
individual AHU control panels in their respective AHU Rooms.

b) Check the oil heater - It must be energized for 12 hours prior to starting the chiller.

c) Check the incoming water of the Expansion Tank installed at the roof level of the klinik
building.

d) Check the water level of the Air-con Expansion Tank.. The water level must be at least half
full. The isolation valve of the Expansion Tank must be open to ensure the chilled water
piping system is completely filled up.

e) Check the incoming water to the Air-con Make-up Tank to ensure the continuous supply of
water. The water level of the Air-con Water Tank supplying to Cooling Towers must be at
least half filled to ensure continuous supply of water to the Cooling Towers.

f) The FCU(s) and AHU(s) must be switched on to provide sufficient load to the Chiller.

g) There are two ways of switching on the AHU(s). The selection switch on the control panel
can be switched to local (means manual - manually press the start or stop button) or Auto
(means by switch on by BMS -not provided).

h) The Chiller can be started in two ways. The selection switches on the MSB (Main Switch
Board) for Cooling Towers, Condensing Water Pumps, and Chilled Water Pumps can be
selected for Manual, Neutral or Auto. If the selection is manual, the Chiller can be started
manually by following the correct sequence of operation.

The correct sequence of the operation of the Chiller.

TURNING ON AC SYSTEM PROCEDURE

WORK FLOW DESCRIPTION REMARKS
STEP 1 Turn On AHU(s) / FCU(s) Turn On at AHU/ FCU Panel
STEP 2 Turn On COOLING TOWER Turn On at ACMSB Panel
STEP 3 Turn On CONDENSING WATER PUMP Turn On at ACMSB Panel
STEP 4 Turn On CHILLED WATER PUMP Turn On at ACMSB Panel
STEP 5 Turn On CHILLER Turn On at Chiller Panel

TURNING OFF AC SYSTEM PROCEDURE

WORK FLOW DESCRIPTION REMARKS
STEP 1 Turn Off CHILLER Turn Off at Chiller Panel
STEP 2 Turn Off CHILLED WATER PUMP Turn Off at ACMSB Panel
STEP 3 Turn Off COffDENSING WATER PUMP Turn Off at ACMSB Panel
STEP 4 Turn Off COOLING TOWER Turn Off at ACMSB Panel
STEP 5 Turn Off AHU(s) / FCU(s) Turn Off at AHU/ FCU Panel

i) The Condenser tube cleaner can only be done during the chiller shutdown.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

Operation Procedure

B. AIR-CONDITIONING SYSTEM — Split Air-cooled Air-conditioning unit.

1. Switch on the Air-con switch for the power supply. Press ON/OFF on the remote controller
to turn on or off the Air-cooled Air-conditioning unit. The target room temperature can be set on
the Remote Controller. Other functions like timer, Fan speed, and other mode of operation can be
set on the Remote controller.

C. MECHANICAL VENTILATION SYSTEM

1. Check power supply for the control panels of the Fans (Fresh air and Exhaust).

2. START the fan by pressing start button on the control panel. Stop the fan by pressing
stop button.

3. For single-phase exhaust fans, turn ON/Off at lighting switch.

OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

SECTION 3

Operator’s
Knowledge

Operator's Knowledge
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

3. OPERATOR'S KNOWLEDGE
Operator should be familiar with the following equipments: -

1. The function of each of the Air-Conditioning Equipment's

Namely a. Chiller
b. Cooling Tower
c. Chilled Water Pumps
d. Condensing Water Pumps
e. Air Handling Unit (AHU's)
f. Fan Coil Unit (FCU's)
g. Air-cooled Split Air-conditioning units.
h. Ventilation Fan and the area it serves.
2. The powers supply to the following Switchboard and control panels.

a) Air-con Main Switchboard (MSB),

Power supply to:-
- Condensing water Pump,
- Chilled Water Pump,
- Cooling Tower,
- Chemical Dosing Pump,
b) Individual control panel of AHU(s),
c) Ventilation Fan Control Panel,
d) Thermostat of the Fan Coil Units (FCU(s).

3. The sequence of system control for the equipments in manual and in automatic mode.

4. The location of the Isolating valves and motorized Zoning Valves for the chilled water
piping as indicated in the as-built drawing.

5. Location of all equipment's as listed in item (1) above and their control panels as described
in system overview and indicated in the as-built drawings.

6. Constant monitoring of the consumption of chemical solution into the condensing-water

system by Chemical dosing pump at the Chillers plant room.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

IMPORTANT MONITORING WORK

Make sure chiller and cooling tower is checked every 1 hour

ITEMS DESCRIPTION
Important Readings from chiller 1. Leaving Evaporator Water Temperature (LEWT)
~ approx 44 deg F
2. Entering Evaporator Water Temperature (EEWT)
~ approx 54 deg F
3. Leaving Condenser Water Temperature (LCWT)
~ approx 97 deg F
4. Entering Condenser Water Temperature (ECWT)
~ approx 87 deg F
5. EEWT – LEWT
~ approx 10 deg F
6. LCWT – ECWT
~ approx 9.2 deg F
Make sure cooling tower water Chiller will trip if there is no water in cooling tower
make up tank is at least ¾ full
Make sure load is more that 50% Chiller may trip if condition not met

TROUBLESHOOTING

AHU
Cannot switch on 1. Check power supply
2. Check for power trip in control panel
Not cold 1. Check motorized valve is in open position
2. Check incoming and leaving water temperature( the difference should
be 10 deg F)
3. Check unusual external sources of heat, e.g doors or windows not
closed, too many people
4. Check for blockage in air cond ducting

FCU
Cannot switch on 1. Check power supply
2. Check for power trip in DB
Not cold 1. Check for proper temperature setting. (Thermostat dial is from 10 to 35
representing the desired temperature) Inexperienced users often
confused 35 as maximum cooling and 10 as minimum cooling.
2. Check motorized valve is in open position
3. Check unusual external sources of heat, e.g doors or windows not
closed, too many people
4. Check for blockage in air cond ducting
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

SECTION 4

Maintenance
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

Maintenance

4. MAINTENANCE
In general, daily Operation logbooks for all major equipments must be implemented to detect any
abnormality of the equipments. A good planned program of regularly scheduled maintenance is
recommended to maintain the good running condition of all the equipments. The following scheduled
maintenance for individual equipments are listed for implementation.

A. CHILLERS

An operating logbook for individual chiller is recommended. Daily record of system

operating conditions (temperatures and pressures) must be recorded at regular intervals
throughout the 24 hours operating period.

Daily maintenance
1. Check the Microcomputer Control Center display for any alarm. Rectify the problem
if any. Record the fault.
2. Check the bearing oil pressure on the SYSTEM Screen. Record it on the logbook.
3. Check the operating oil level. It should be between the upper and the lower sight
glass. Drain or add if necessary. Record it on the logbook.
4. Check entering and leaving condenser water pressures and temperatures. The
temperature can be checked on the SYSTEM Screen. Record it on the logbook.
5. Check the entering and leaving chilled water temperatures and evaporator 's pressure
on the SYSTEM Screen. Record it on the logbook.
6. Check the condenser saturation temperature on the SYSTEM Screen. Record it on
the logbook.
7. Check the compressor discharge temperature on the SYSTEM Screen. It should not
exceed 104 deg C (220 deg F). Record it on the logbook.
8. Check the compressor motor current on the SYSTEM Screen. Record it on the
logbook.
9. Check the temperature difference between the water leaving condenser and saturated
condensing temperature. It should not exceed by more than 2.2 deg C (4 deg F).
Record it on the logbook.

Weekly Maintenance
7. Check the refrigerant charge during shut down of the chiller. The refrigerant charge
level should be visible in the sight glass. This should only be done at least 4 hours
after shut down.
8. Check for any leakage of the entire chiller.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

Maintenance
Annual Maintenance
1. Drain and replace the oil in the compressor oil sump.Inspect and clean water
strainers of the Evaporator and Condenser.
2. Inspect and clean tubes as required.

B. CHILLED WATER and CONDENSING WATER pumps.

Monthly Maintenance.

3. Checks pump glands/seal for leakage and bearings for excessive noise, wear and
temperature and lubricate with oil grease as and when necessary.
4. Check alignment and adjust as necessary.
5. Check lubrication.
6. Check all bolts and nuts for tightness and tighter as and when necessary.
7. Check pumps motor operation and measure running AMPERE adjust or rectify as
necessary.

C. COOLING TOWERS

Daily maintenance

1. Check the water level of the make-up tank. It should be at least half filled.
2. Check for abnormal vibration and noise, burning smell from the cooling tower.
Inspect the source and rectify immediately.
3. Check the incoming and outgoing water temperature If abnormal, inspect and rectify
the problem immediately.
4. Top up the chemical solution at the plant room and record the consumption daily.

Quarterly Maintenance.

1. Clean the hot water basin distribution holes and strainer to avoid clogging.
2. Check the fan bearings and replenish the grease if necessary.
3. Check the tension of the fan belt; adjust if necessary by shifting the fan motor
position. Replace the belt if the belt is worn-out or elongated.
4. Check fan blades for dust and other deposit. Clean the blades to avoid unbalance
operation of the fan.
5. Clean the louvers.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

Maintenance

D. AIR HANDLING UNIT

Quarterly Maintenance

1. Check and clean filters, replace as necessary.

2. Check for abnormal bearing or moving components noise level, rectify or replace as
necessary.
3. Check alignment for belting and pulleys.
4. Check for wear and tightness of belting. Adjuster or replace as necessary.
5. Check coils and associated piping connections for leakage and purge air from coils.
6. Check drips trays and drains and cleans as necessary.
7. Check and clean strainers to the cooling coil.

E. CHILLED WATER FAN COIL UNITS

Quarterly Maintenance.

1. Check all filter, clean or replace as necessary.

2. Check cooling coil and strainer, clean as necessary.
3. Check for proper functioning of ON/OFF valve and thermostat, adjust or replace as
necessary.

F. SWITCHBOARDS / CONTROL PANELs

Annually maintenance

1. Record readings of all hour run meters, voltmeters and ammeters.

2. Check all starters, contactors and relays for bad contact, clean or replace as necessary.
3. Check control sequence operation. Adjust sequential timing as necessary.
4. Check operation of all test switches and automatic devices and adjust as necessary.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

Maintenance

G. AIR-COOLED SPLIT AIR-CONDITIONING UNIT.

Quarterly Maintenance

3. Clean air filter and replace whenever necessary.

4. Check the running ampere of the compressor.
5. Clean the condensing coil.
6. Check the function of the fan coil unit.
7. Check the pressure of the R22 Refrigerant. Top up the Refrigerant whenever
required.

H. EXHAUST FAN

Yearly Maintenance

1. Grease the bearings if necessary.

OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

SECTION 5

Water
Treatment
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

Water Treament

5. WATER TREAMENT

(A) Condensing Water

Daily dosage
-To top up the chemical mixture solution of the tank (located at the plant room)
based on the recommended dosage by the water treatment specialist.

Monthly water sample analysis

The appointed specialist will take water sample from the cooling tower for analysis.
A recommended dosage will be provided. If necessary, drain the water from the
basin of the cooling tower if it is required.

(B) Chilled Water

Annually water sample analysis

The appointed specialist will take chilled water sample from the plant room for
analysis. A recommended chemicals dosage will be added into the chilled water
system.
OPERATION AND MAINTENANCE MANUAL
KLINIK & PEJABAT TAWAU ACMV O&M

SECTION 6

List Of
Equipment
(Appendix)