11. Carry out testing by “Test” mode of TCMS and check that there is noinformation for fault. 5.7.2.2 Printed circuit boards of CPU unit (0.3 man-hours) CPU unit consists of four PCB below and one back board which connect PCBs. 1) CPU board 2) HDLC transmission board 3) I/O board 4)Power supply board 1. Turn off all power to the ACCP. Install safety tags on system power sources to alert other personnel work is in progress on the air conditioning unit. 2. Keep all removed bolts and screws for reuse. 3. Remove all electric connector on the front of CPU unit 4. Cut and remove cable ties used for the cable fixing. 5. Loosen bolts fixing the bar plate which press PCB and remove three (3) bar plates. 6. Pull out PCB in front. 7. Install new PCB, fix the bar plate with bolts and tighten bolts. 8. Connect all electric connector. 9. Connect PTU unit. 10. Turn on all power to ACCPC and check the lighting of indication lamp “CPU RUN” at the switch/display panel which shows the health of CPU. 11. Check that there is not “Transmission error” information on the display of TCMS and PTU. 12. Carry out testing by “Test” mode of TCMS and check that there is noinformation for fault.
60 Workshop maintenance manual The Workshop Maintenance Manual is intended for use by workshop maintenance staff on overhaul, disassembly and / or reassembly of ventilation and air conditioning component parts. This manual contains information on how to perform bench testing, final inspection and packaging of a serviced item before sending it back to first line maintenance team or store or manufacturer for repair or other service actions. 61 Overhaul and refurbishment planning data Please refer to Section 3 Maintenance planning data for the overhaul and refurbishment planning information. 62 Overhaul and refurbishment implementation 5.8.2.1 Disassembling and reassembling of condenser fan (0.6 man-hours) Refer to Figure 47- Figure 54 1. Keep all removed bolts, screws and parts for reuse. 2. Remove the outer components, wall ring (6) and grille frame (5a) check that they can be reused. Figure 47 – Outer components
3. Detach the screw connection (305 / 306), also detach the cable screw connection (3) and remove the stator flange (4). 4. Remove the circlip (302b). Figure 48 – Outer components 5. Separate the stator (1) and the impeller (2) from one another using the bar extractor (Figure 49). 6. Note the position and number of washers for reassemble the unit later. 7. The ball bearing (301 b) can normally be pushed out by tapping lightly with the head of a hammer. Avoid tilting otherwise the bearing seat to the stator will be damaged. 8. Once the circlip (302a) has been removed, pull out the ball bearing (301 a) using the bar extractor and the extractor sleeve. (Attention: Shaft (202) cannot be removed.) 9. Also remove the Nilos ring (307), if there is one, between the ball bearing (301 a) and the rotor hub (2) (see Figure 43).
Figure 49 – Stator and impeller Figure 50 – Bearing Figure 51 – Nilos Ring 10. Check Nilos ring for damage. 11. Apply moisture-resistant grease (e.g. Kluber Staburags Asonic GHY72) to grease groove. 12. Push it onto the shaft with the grease groove in the direction of the ball bearing (301 a). 13. Continue to assemble by following the steps for dismantling in reverse order.
14. Apply grease to bearing seats 15. Press-in ball bearing (301 a) using press-in sleeve, see Figure 44. 16. Ensure that position and number of washers (304) are identical to position and number when the condenser fan is dismantled. 17. Join stator (1) and rotor (2) by hand. 18. Install circlip (302a) press-in ball bearing (301 b) using press-in sleeve. Figure 52 – Bearing installation 19. Install circlip (302b) ensure that the circlip is fitted correctly to the shaft groove. 20. Tightening Torque of M6 screw: (min. 9Nm / max. 12Nm ) 21. Assemble the cable screw connection (3). It is essential to ensure that the terminal box or cable screw connections are carefully insulated from moisture. Check that existing seals can be reused safety. 22. Add-on the external components such as wall ring or wire screen. 23. Secure the screw connections 20 and 22 with Loctite Prod. No. 542. 24. Check that the gap between the blade (2) and the wall ring (6) is even. 25. Connect the unit to power supply and carry out a function check.
Figure 53 – Adding external components Figure 54 – Gap 5.8.2.2 Disassembling and reassembling for evaporator fan (0.8 man-hours) Refer Figure 55 to Figure 60 1. Loosen six M5 screws and remove inlet ring near motor. Store for reuse. 2. Loosen the two M16 nuts on the motor shaft. Store for reuse.
3. Remove the fan wheel from the motor shaft using a pulley extractor. 4. Remove the key (2) from the motor shaft (1). 5. Loosen and remove hexagon nuts from bolt (3). Store nuts, flat washer and spring washer for reuse. 6. Remove the bearing brackets (4) and the collar for the drainer (5) from the motor casing (12). 7. If bracket (4) is too tightly connected to be removed with hands, loosen it by tapping with a wood hammer. 8. Pull the rotor assembly (6) off the stator assembly (7). Take care not to damage the winding of the stator assembly (7) while pulling the rotor assembly (6). 9. Remove a flat spacer (8), (10) and four conical springs (9) from other side bearing bracket. Please record the direction of four conical springs. Store spacers and conical springs for reuse. 10. Pull the ball bearing (11) off from the rotor assembly (7) using a pulley extractor. Hook the pulley extractor symmetrically on the inner wheel of the bearings.
Figure 56 – Remove fan wheel Figure 58 – Force-fit tool 11. When blower motor is reassembled, set each ball bearing (11) right-angled to the rotor assemble (6). 12. Force fit the bearing by pushing the inner race with a force-fit tool. 13. After force-fitted, lightly rotate the bearings with hand and check for any abnormality. 14. Apply ENS grease when the bracket is installed. Do not allow grease inside the housing. 15. Apply ENS grease on the both surface of each conical springs.
16. Install a flat spacer, 0.35t, (8), two new conical springs (9), a flat washer, 0.8t, (10) and two new conical springs (9) in opposite direction. 17. Wipe dust and dirt off the rotor assembly (6). Insert the rotor assembly (6) into the stator assembly (7). 18. Check that the rotor assembly (6) is correctly positioned. 19. Wipe dirt and old grease off the bearing housing on the bearing brackets. 20. Apply new grease in the housing pockets. Use ENS grease. Do not allow grease inside the housing. 21. Attach the bracket (4) to the motor casing (12) and fix with hexagon nut, flat washer and spring washer (3). 22. If not lightly fitting in, tap the bracket with a wood hammer. 23. Install new drainer (5). 24. Uniformly tighten three bolts to prevent uneven tightening. After tightened, manually rotate the shaft and check for any normality. 25. Put the key (2) back onto the motor shaft (1). 26. To reassembling the blower, fix the motor on the blower base with bolts. 27. Fit the fan wheels onto the motor shaft and connect them with the M16 nut. 28. Fit the inlet ring with screws (M5 screw). 29. Ensure the rotational direction of the two fan-wheels is correct. The blades and the thread of the two M12 nuts are threaded the opposite way. 30. Connect the unit to power supply and carry out a function check. 5.8.2.3 Replacement of geared motor for F/R air damper (0.25 man-hours) 1. Move the damper blade to the closed position of fresh air inlet. 2. Loosen and remove M4 screws. Store for reuse. 3. Separate the geared box from damper body. 4. Remove the electric connector from motor 5. Loosen and remove M4 screw for motor fixation. 6. Attach new motor with pinion gear and fix with M4 screw.
7. Assemble the damper reversing the removal procedure. Figure 59 – F/R air damper motor 5.8.2.4 Replacement of geared motor for emergency damper (0.25 man-hours) Refer to Figure 60- Figure 65 1. Remove geared motor cover of emergency damper by loosening M4 screws. 2. Remove the position switch unit which is fixed engagement to motor body. It can be removed by hand.
Figure 60 – Geared motor for emergency damper Figure 61 – Geared motor for emergency damper 3. Record the relation of position between fix plate and damper blade. Loosen and remove bolts and screws, and remove all fixing plates shown in Figure.62
Figure 62 – Bolt, screw and fixing plate to be removed 4. Loosen bolts and move the plate in the direction of arrow shown in, and pull out geared motor in front Figure 63 –Screws to be loosen and plate to be move 5. Install a new motor and fix motor with reverse procedure of removing. After fixation, make sure that the projections of protection tube are stuck properly in holes. Figure 64 –Protection tube 6. Reattach the cover for geared motor using screws and tighten screws with rated torque.
5.8.2.5 Replacement of geared motor for CAHU damper (0.4 man-hours) 1. Remove the geared motor cover by loosening M4 screws shown in Figure 65 2. Remove the electric connector at PCB of DC/DC converter. 3. Loosen nut and remove a screw for removal of plate for motor fixing on backside. 63 Software system manual Not applicable. 64 Testing procedure for workshop Before installation of ACU, carry out the testing by using the bench test unit (BTU).