Service Bulletin

Service Bulletin
REPAIR OF CHILLED WATER PIPING AT QUALCOMM BLDG W
Objective
The objective of this Service Bulletin is to describe the procedures required to repair a problem
with the chilled water piping. Units affected by this Service Bulletin are site specific to Qualcomm
Bldg W.
Problem
Qualcomm has (44) FM40B-CKA-XXD-QCOM units installed. The valve vendor had an entire lot
of bad valves leak requiring all 44 assemblies be replaced. In addition, due to an error in the site
submittal, the supply and return lines are reversed.
Solution
The solution for both issues is to remove the existing piping from the unit and replace with the
new piping assemblies. The piping vendor was issued corrective actions to address the valve
leak. The piping vendor now has a thread they use to pretest valves, uses a new procedure to
clean the threads, and uses a new testing standard with helium and a mass spectrometer. In
addition, APC has also updated its test procedures to use helium and a mass spectrometer to
check for leaks. The new piping assembly also correctly aligns the return and supply lines.
Human Resource Requirements
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APC Engineer familiar with the product and the electrical panels
APC Global Services Field Service Engineer
Third party APC certified Service Provider
All parties associated with the rework procedure are subject to the site rules as defined by Roel.
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Vehicles may not be parked at the work site. Equipment may be dropped off then the
vehicles must park on the street.
All persons shall wear boots
All persons shall wear hard hats
All persons shall wear protective eyewear
All tools and parts must be kept orderly
Required Tools
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Cordless Drills
Extension Cords
Brazing equipment
Pipe Cutters – close quarter jab saw or bow saw
Soft Solder – Staybrite 8 or equivalent
(3) T30 Torx bit
(3) T20 Torx bit (long)
10mm socket
#2 Phillips screwdriver
#2 Standard screwdriver
Armaflex Insulation Glue
Measuring Jigs
Pressure Regulator
Extractors
Wire Stripper
Crimper
Heat Shield
Fire Extinguisher
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Required Parts
• (46) sets of (4) pipe assemblies – A, B, C, D (shown below)
• Additional Insulation
• Extra Actuator
• Extra Gasket Material
• Assorted Fasteners (T20, T30, 10mm, M4 nuts, M4/M6 screws)
• Extra Electrical Pins
• Extra Electrical Sockets
• Touch Up Paint
Pipe Assembly “A”
Pipe Assembly “B”
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Pipe Assembly “C”
Pipe Assembly “D”
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Rework Instructions (3 Hrs per Unit)
Unit Disassembly Instructions
1) Remove shunt trip harness P61 from LH front door, then remove LH door by pulling the
pin down to release the door, repeat for RH and CTR doors.
2) Remove LH, RH, and then CTR airblocks. If needed remove T20 Torx screw in top center
of each airblock.
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3) Remove airblock support by removing the T30 Torx screw on each end. (2) Total.
4) Detach from main circuit breaker the main power wiring (be sure all power to unit is off)
using a #2 Phillips screwdriver
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5) Disconnect all harnesses in bottom of control box 0w1523, 0w1517, 0w1533a, 0w02342,
DB25 cable. These snap in and out by pressing on each side of connector.
6) Push all harness connectors out of the bottom of the box. (it helps to use a flat tip screw
driver to push in the tabs on the connectors. The DB25 may remain, just be careful not to
damage the connector when removing the e-box.
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7) Disconnect the blower wires from the VFD’s by using the #2 Phillips screwdriver
8) Remove (4) nuts from the studs that hold the control box in by using the 10mm socket.
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9) Remove the (2) T20 screws that go through the control box in to the fan divider airblock.
10) Lift out and place the control box away from unit
11) Remove RH control box bracket by removing the (3) T30 Torx screws.
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12) Remove (8) T30 Torx screws on the RH blower and then remove the Blower from unit.
Be careful to not damage the blower gasket when removing. Do NOT slide blower!
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Piping Operation Instructions
1) Remove the actuator by loosening the retaining bolts and disconnecting the wire
harness.
2) In the following operations, always make pipe cuts perpendicular/transverse to the
direction of the pipe and use the measuring gage supplied by APC.
3) Cut the pipes at 3.5 inches above the base pan of the unit.
4) 3Cut the rear pipes in the unit 14.5 inches above the blower shelf and cut the front
pipe 17 inches above the blower shelf.
5) Remove old piping assembly.
6) Place pipe assembly “A” in the rear of the unit (this is now the inlet pipe) It will
cross over with pipe assembly “D” and be piped to the coil in the front.
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7) Put in pipe assembly “D” that attaches to front coil pipe.
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8) Put in pipe assembly “B” that has the actuator bracket.
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9) Mate in pipe assembly “C”.
10) Solder in piping assemblies and test all solder joints for leaks and then replace the
insulation on the pipes as necessary.
11) Replace actuator and reconnect wiring harness to actuator.
Completed Piping Assembly (A, B, C, D)
Completed Piping Assembly shown in unit.
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Unit Reassembly Instructions
1) Put blower back in by using the T30 Torx screws that were removed in step 12.
2) Install RH control box bracket by using the (2) T30 Torx screws from step 3.
3) Install control box, attaching with the (4) nuts that were removed in step 8.
4) Install the 2 screws that hold the blower divider with the T20 Torx bit and screws from
step 9.
5) Install all wiring harnesses in bottom of control box that were removed in step 6.
6) Connect all harnesses back that were removed from step 5.
7) Wire the blowers back up being sure that all wires go to correct place on VFD.
8) Re-connect the main power wiring using the Phillips screwdriver.
9) Install the CTR airblock by fitting the raised lance in to the square cutout in coil frame,
then attach the RH and LH airblock the same way and also mating the lance in the CTR
airblock as well as the unit corner posts.
10) Install the LH door and connect the shunt trim harness P61.
11) Install the CTR and RH doors.
The unit will then be leak checked by pressurizing the unit to 100psi with CO2 and then
checked with soap bubbles. After returning power to the unit, the actuator will then be tested
to assure normal operation.
Priority
This Service Bulletin must be implemented ASAP at Qualcomm Bldg W.
Financial Aspect
APC is responsible for all financial aspects of this repair.
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