BEST OPERATIONAL PERFORMANCE

BY MAINTENANCE

Building Automation System

 YAMATAKE
GROUP
CORPORATE
PROFILE
Since its founding in 1906, the Yamatake Group

has built on its core of measurement and control

technologies to maintain its position at the

forefront of Japan’s automation industry. To our

Founded by Yamaguchi Takehiko
customers, Yamatake is a name to depend on for optimum solutions in

industrial automation, building automation, and factory automation.

As Japan’s leading supplier of

Building Automation, Yamatake

Building System Co., Ltd provides

integrated air conditioning, lighting,

sanitation, security, access, and fire

systems monitoring and control to

office buildings, hotels, factories, laboratories, schools, and hospitals.

Our highly advanced

products and systems can

improve the value of your

investment. Wether you operate

a refining plant, a factory or an

office building, Yamatake is

dedicated to helping you to enhance productivity, safety and

convenience while conserving energy usage and running costs.

 OVERVIEW
PT. YAMATAKE BERCA
INDONESIA

Yamatake has been serving the Indonesian

market since 1970s, together with PT. Berca

Indonesia. The commitment grows further in

strength in a joint venture between Yamatake

Corporation and PT. Berca Indonesia.

PT. Yamatake Berca Indonesia was formed in 1997 to enable us to

work more closely with Indonesian customers in engineering and

support of optimal automation solutions. Since its founding, we have

been serving Indonesian customers in a wide range of business, from

industrial control, building management, factory automation to control

components.

We grew in strength and versatility

after P.T. Berca Indonesia became

Yamatake’s distributor, in 1974. Since then,

we have aided progress in such process

industries as oil refining, chemical, power, pulp & paper and food

processing. We have helped to improve built environments for hotels,

offices, factories, government and shopping centers.

PT. Yamatake Berca Indonesia is commited to offering SOLUTION to
the Indonesian market, that is,

S olving complex problems in instrumentation by providing world-

class consulting from the earliest stages of design and
implementation

O pen and advanced technologies and state-of-the-art products for

the latest automation solutions

L arger variety of products and systems provided, such as sensors,

controllers, control valve and open architecture systems

U tilizing customer investment at the best by offering complete

after-sales services

T otal quality concept is tightly integrated in design, manufacturing,

sales and service

I mproving productivity, safety, profitability, comfort and

environmental compliance in your plants and facilities

O ne-stop shopping for automation solution products at competitive

prices is our commitment to customers
N ever forget to compromise on energy and environmental
conservation

BUILDING AUTOMATION

PERFECTING ENVIRONMENTS

B uilding
comprehensively
Automation is a system for

controlling and managing a variety of facilities in a building. Central

monitoring systems, which monitor the operating status and errors of

building facilities such as air handling, heat sources, plumbing and

power facilities plus what has up to now been called automatic control

equipment of air handling, have now been integrated into one

centralized piece of equipment with the advance of computer

technology and improvements in digital communication technology,

resulting in centralized monitoring and control of all the facilities in a

building.

Centralized equipment is now called an

Integrated BA System,

which monitors an

expanding number of

facilities, from lighting,

elevator facilities, fire facilities, and security facilities such as access

control or intrusion monitoring to user terminals. It has also expanded

into a system called a Building Management System which controls

information on the entire building and its facilities and ensures their

effective operation.

Modern buildings

are changing the way the world works.

In the way their internal workings can

adapt to ambient air quality and

temperature conditions, they have become a business asset that can

enhance the comfort and boost the productivity of occupants.

At Yamatake, we know that buildings represent significant assets

on your balance sheet – and as such, making a profit must be a

measure of performance.
 M AINTENANCE

Preventive maintenance refers to a series

of actions that are

performed on either a time-based schedule or a schedule based on

that of machine run time. These actions are designed to detect,

preclude, or mitigate degradation of a system (or its components). The

goal of a preventive maintenance approach is to minimize system and

component degradation and thus sustain or extend the useful life of

the equipment.

Building

automation integration of sensors – for

temperature, humidity and comfort

measurement – security devices, HVAC

controls, valves and actuators,and heat

source control networked with a central control system, ensure

efficient, safe, energy – cones.ving operations throughout the building.

To keep your investment operating at peak performance throughout its

lifecycle, PT. Yamatake Berca Indonesia offers a comprehensive service

and support program tailored for your particular needs.

One case for example to explain why

maintenance is very important in the

control system, its the control valve,

which is the most important

equipment in your control system that

constantly in contact with the process medium. Therefore the control

valve has a significant impact on your plant’s efficiency and if not

properly maintained, it will perform like a well tuned car with bad tires

– capable of running but becoming very

dangerous during sudden braking.

Our engineers can assist the

condition of your control valve and provide

recommendation for service or overhaul.

Beside that the ability of an Energy Management Control System

(EMCS) to efficiently control energy use in a building is a direct function

of the data provided to the EMCS. The value of an EMCS in making

decisions is dependent upon the accuracy of the information in the

system. Therefore careful input of accurate, up-to date data is

essential.
 For a number of reasons, the calibration of

sensors is an often overlooked activity.

However, sensors should be calibrated

regularly as sensors out of calibration can lead

to enormous energy penalties. Furthermore, as with steam traps, these

penalties can go undetected for years without a proactive maintenance

program.

PURPOSE OF MAINTENANCE
 Prevents functional disorder and failure

 Enables detection of parts deterioration problems and trouble

parts

 Replaces consumable parts, or parts which are judged likely to

break down

 Enables calibration and readjustment of the sensors and

actuators

 Keep the equipment in good working condition

BENEFITS OF MAINTENANCE
  Extends effective operational life of equipment

 Generates energy saving

 Prevents plant shutdown from unexpected accidents due to

instrument trouble

 Increases the realibility, availability and safety of the

instrument

 Enables making an efficient maintenance budget for parts and

service

 Reduces equipment and/or process failure

KEY COMPONENTS
Modern control systems have three necessary elements : sensors,

controllers, and the controlled devices.

Component Description
Sensors There is an increasing variety and level of
sophistification of sensors available for use
with modern control systems. Some of the
more common include : temperature, humidity,
pressure, flow rate, and power. Sensors that
track indoor air quality, lighting level, and fire
 or smoke are becoming more common.
Controllers The function of the controller is to compare a
signal received from the sensor to a desired
setpoint, and then send out a corresponding
signal to the controlled device for action.
Controllers may be very simple, such as a
thermostat where the sensor and controller are
usually co-located, to very sophisticated
microprocessor based systems capable of
powerful analysis routines
Controlled Devices The controlled device is the terminal device
receiving the signal from the controller.
Amongst others, typical controlled devices
include : air dampers, mixing boxes, control
valves, and in some cases, fans, pumps and
motors

MAINTENANCE PROGRAM
Asophisticated maintenance program for preventive services

provides :

• PERIODIC INSPECTION AND VERIFICATION

Checking that systems and field

instruments perform according to

specifications will ensure that your

plan continues to improve the

productivity of your business.

• CALIBRATION CHECKS

Field instruments require such periodic calibration as zeroing,

ranging, and span adjustment

• MODIFICATIONS TO MEET NEW REGULATIONS AND

STANDARDS

With new legislation on quality and environmental management

come new burdens on manufacturing and building industries; we

can ease your burden by assuring compliance – before inspectors

come by.

•ANALYSIS OF FAILURE RECORDS

When things go wrong, our experienced service

engineers can pin point the problem from analysis

of the system status report and other records.

• PARTS REPLACEMENT

Should unforeseen trouble occur, spare parts readily

are available. Any defective parts are replaced

according to service agreements, and detailed failure analysis are

presented as required.

MAINTENANCE SCHEDULE
Maintenance Frequency
Description Comment Semi
Daily Weekly Monthly Annually
Annually

Complete overall visual

Overall
inspection to be sure all
visual X
equipment is operating and that
inspection
safety systems are in place

Verify Verify in control software that

control schedules are accurate for X
schedules season and occupancy

Verify in control software that

Verify
setpoints are accurate for X
setpoints
season and occupancy
 Check all Check all gauges to make sure
X
gauges readings are as expected
Check
outside air Check for proper function X
volumes
Check Temperature should not exceed
X
setpoints or drop below design limits

Verify the bottom, surface and

Check
water column blow downs are X
schedules
occurring and are effective

Assure that all deadbands are

Check accurate and that the only
X
deadbands simultaneous heating and
cooling is by design

Conduct through check of all

Check sensors for temperature,
X
sensors pressure, humidity and flow for
expected values

Calibrate all sensors for

Calibrate
temperature, pressure, humidity X
sensors
and flow

MAINTENANCE PROCEDURE

MAINTENANCE OF

MAIN CENTRAL UNIT

( MCU )

• Maintenance Of Software
 Work Sequence Detail Detail Work Tools

Assign for • The equipment

maintenance concerned should be
assigned as control
points under
maintenance

Historical • The data of the latest

HistoricalTrend
Trend 48 hours is shown in
Check
Check a historical trend
graph (totalizer point
is shown in bar chart)

Control Point • Check the control

Check point on the Graphic
screen
• Check point function
• Check equipment
schedule
• Modify setpoint value
• Check the value

Check The Sight • Check the sight of the

equipment and
facilities

• Maintenance Of Harddisk

Work Sequence Detail Work Detail Work Tools

Hard disk The condition of MCU

must be on

Move to the graphic

Checking screen display screen several times and
make sure that the
screen is displayed
normally.

Checking for abnormal Check Whether the hard

disk drive generates
noise
abnormal noise
compared with its initial
state.
 MAINTENANCE OF DDC CONTROLLER

• Intelligent Digital Controller ( IDC )

Work Sequence Detail Detail Work Tools

• Check Power input from UPS Data Setter, Digital
• Power signal check. tester, Srew driver
IDC
• Check indication on/off line.
• Check the Installation of the
IDC and its I/O slots
• The sequence of I/O slot
should follow the design of
point assignment

• Connect the data setter to the

IDC data plug
• Error check.
• Function check
Test Function
• Operation check
IDC
• Counter check of the I/O point
and 1 by 2 sheet
• Check the reading data setter
of I/O point

• Maintenance Of Intelligent Data

Gathering Panel ( IDGP )

Work Sequence Detail Work Detail Work Tools

 • Check Power input from Data Setter, Digital
UPS tester, Srew driver
IDGP • Power signal check.
• Check indication on/off
line.
• Check the Installation of
the IDGP and its I/O slots
• The sequence of I/O slot
should follow the design
of point assignment

• Connect the data setter to

the IDGP data plug
• Error check.
Test Function • Function check
IDGP • Operation check
• Counter check of the I/O
point and 1 by 2 sheet
• Check the reading data
setter of I/O point

• Maintenance Of Digital Output

Module

Work Sequence Detail Work Detail Work Tools

 Data Setter, Digital
Digital output module • Check tester, Srew driver
connection terminal cable
control

Contact
Contactoutput
outputcheck
check • Counter check of the I/O
point and 1 by 2 sheet

Test Function DO module • Connect the data setter to

the IDGP data plug
• Error check.
• Function check
• Operation check
• Check the reading data
setter of DO point

• Maintenance Of Digital Input Module

Work Sequence Detail Work Detail Work Tools

Data Setter, Digital
Digital • Check tester, Srew driver
Digitalinput
inputmodule
module connection terminal cable
control

Contact
Contactinput
inputcheck
check • Counter check of the I/O
point and 1 by 2 sheet

• Connect the data setter to

Test Function DI module the IDGP data plug
• Error check.
• Function check
• Operation check
• Check the reading data
 setter of DI point

• Maintenance Of Analog Output

Module

Work Sequence Detail Work Detail Work Tools

Data Setter, Digital
Analog • Check tester, Srew driver
Analogoutput
outputmodule
module connection terminal cable
control

Signal
Signalcheck
check • Check signal output of
AO module

• Connect the data setter to

Test Function AO the IDGP data plug
module
• Error check.
• Function check
• Operation check
• Check the reading data
setter of AO point
• Maintenance Of Analog Input Module

Work Sequence Detail Work Detail Work Tools

Data Setter, Digital
Analog • Check tester, Srew driver
Analoginput
inputmodule
module connection terminal cable
control

Signal • Check signal input of AI

Signalcheck
check module

• Connect the data setter to

Test
TestFunction
FunctionAI
AImodule
module the IDGP data plug
• Error check.
• Function check
• Operation check
• Check the reading data
setter of AI point
MAINTENANCE OF THE ACTUATOR

• Maintenance Of Control Valve

Work Sequence Detail Work Detail Work Tools

Cleaning
Cleaningbody
Cleaning body. Brush, WD-40.
body
Motorized Valve Cleaning terminal cable.
Motorized Valve

Check Check connection terminal Screw driver

Check Cable control.
connection
connectionterminal
terminal
cable control
cable control

Data setter, Digital

Check signal input 2 to 10 tester
Test vdc from controller.
Testfunction
functionMotorized
Motorized Check position valve from
valve
valve 0% until 100% for
proportional type.
• Maintenance Of Variable Air

Volume ( VAV )

Work Sequence Detail Work Detail Work Tools

Check connection Check connection terminal Screw driver

terminal cable control Cable control

Check function VAV open or close. Data setter,

Test Check Interlock VAV with the AHU Digital tester
Testfunction
functionVAV
VAV System.

MAINTENANCE OF THE FIELD SENSOR

• Maintenance Of Static

Pressure

Work Sequence Detail Work Detail Work Tools

Static
StaticPressure
Pressure • Check the installation of Data setter, Digital
static pressure tester
• Check signal input from
controller
• Check the power supply
of static pressure

• Connect the data setter

Test Function Pressure
• Check the reading data
setter of static pressure

• Maintenance Of Temperature

Sensor

Work Sequence Detail Work Detail Work Tools

 Calibration sensor with Do measuring more than 5 Digital thermometer,
digital minutes until display Data setter
thermometer and display data
setter constant.

Temperature setting.
Compare
Comparethe theactual
actualPVPV
atatdata
data setter withdigital
setter with digital
thermometer
thermometer

• Maintenance Of Ampere Tranducer

Work Sequence Detail Work Detail Work Tools

• Check the installation of Data setter, Digital
Ampere Tranducer Ampere Tranducer tester
• Check signal input from
controller
• Check the power supply
of ampere tranducer

• Connect the data setter

Test Function Ampere
• Check the reading data
Tranducer
setter of ampere
tranducer

• Maintenance Of Voltage

Tranducer

Work Sequence Detail Work Detail Work Tools

 • Check the installation of Data setter, Digital
Voltage Tranducer Voltage Tranducer tester
• Check signal input from
controller
• Check the power supply
of voltage tranducer

• Connect the data setter

Test Function Voltage
• Check the reading data
Tranducer
setter of voltage
tranducer

• Maintenance Of Frequency Tranducer

Work Sequence Detail Work Detail Work Tools

• Check the installation of Data setter, Digital
Frequency Tranducer Frequency Tranducer tester
• Check signal input from
controller
• Check the power supply
of frequency tranducer

• Connect the data setter

Test Function
• Check the reading data
Frequency Tranducer
setter of frequency
tranducer
• Maintenance Of KWh Tranducer

Work Sequence Detail Work Detail Work Tools

• Check the installation of Data setter, Digital
KWh Tranducer KWh Tranducer tester
• Check signal input from
controller
• Check the power supply
of KWh tranducer

• Connect the data setter

Test Function
• Check the reading data
KWhTranducer
setter of KWh tranducer

• Maintenance Of Power Factor Tranducer

Work Sequence Detail Work Detail Work Tools

• Check the installation of Data setter, Digital
Power Factor Power Factor Tranducer tester
• Check signal input from
controller
• Check the power supply
of power factor tranducer

• Connect the data setter

Test Function Power
• Check the reading data
Factor Tranducer setter of power factor
tranducer
MAINTENANCE OFFERING
1. Fully 24 Hours Operating + 2 Times a year
maintenance
 The Operator as YAMATAKE Engineer stand by 24

hours a day and 7 days a week

 The Operator set The Daily Report, Trending,

Maintenance Schedule, etc.

 The Operator will backup data On Line every 1 week
 The Operator overcome the existing daily problems

exclude supply the new parts replacement

  The Operator maintain all of BAS equipments 2 times

a year :
a. The Operator calibrate all of sensors and instruments

every 6 months
b. The Operator make maintenance report every 6

months
c. The Operator check the DDC Controller, Control Panel

and the Installation every 6 months

2. 12 Hours Operating + 2 Times a year

maintenance
 The Operator as YAMATAKE Engineer stand by 12

hours a day and 7 days a week

 The Operator set Daily Report, Trending,
Maintenance Schedule, etc.
 The Operator will backup data On Line every 1 week
 The Operator overcome the existing daily problems

exclude supply the new parts replacement

 The Operator maintain all of BAS equipments 2 times

a year :
a. The Operator calibrate all of sensors and instruments
every 6 months
b. The Operator make maintenance report every 6
months
c. The Operator check the DDC Controller, Control Panel
and the Installation every 6 months

3. Periodic Maintenance ( 2 Times a Year )

  The Operator maintain all of BAS equipments 2
times a year :
a. The Operator calibrate all of sensors and
instruments every 6 months
b. The Operator make maintenance report every 6
months
c. The Operator will backup data On Line
d. The Operator set Daily Report, Trending,
Maintenance Schedule, etc
e. The Operator check the DDC Controller, Control
Panel and the Installation every 6 months

4.Contract Maintenance ( 1 Time a Year )

 The Operator maintain all of BAS equipments 1
time a year :
a. The Operator calibrate all of sensors and
instruments once a year
b. The Operator make maintenance report in 6 months
c. The Operator will backup data On Line
d. The Operator set Daily Report, Trending,
Maintenance Schedule, etc
e. The Operator check the DDC Controller, Control
Panel and the Installation every 6 months
5. Spot Service Maintenance
 The Operator maintain all of BAS equipments once
in visit until finish :
a. The Operator calibrate all of sensors and
instruments
b. The Operator make maintenance report
 c. The Operator will backup data On Line
d. The Operator set Daily Report, Trending,
Maintenance Schedule, etc
e. The Operator check the DDC Controller, Control
Panel and the Installation

6.Emergency Call
A. Emergency Call Stand by 12 hours
 The Operator handle the existing problems only at
08.00 AM – 08.00 PM
 The Operator will make the report
B. Emergency Call Stand by 24 hours ( available only
in town )
 The Operator handle the existing problems in 24
hours
 The Operator will make the report

• Maintenance Of Compact – Data Gathering Panel (

C -DGP)
 Work Sequence Detail Work Detail Work Tools
• Check Power input from Data Setter, Digital
UPS tester, Srew driver
C-DGP • Power signal check.
• Check indication on/off
line.
• Check the Installation of
the C-DGP and Terminal
cable.
• Function check
• Operation check
• Counter check of the I/O
point and 1 by 2 sheet
Test Function • Check the reading data
setter of I/O point
C-DGP

• Maintenance Of Intelligent Fan Coil

Unit ( IFC ).
Work Sequence Detail Work Detail Work Tools
• Check Power input from
IFC UPS Data Setter, Digital
• Power signal check. tester, Srew driver
• Check indication on/off
line.
• Check the Installation of
the IFC and Terminal
cable.
• Function check
• Operation check
• Counter check of the I/O
point and 1 by 2 sheet
Test Function • Check the reading data
IFC setter of I/O point