Operation Manual of AHU

OPERATIONS
&
MAINTENANCE
MANUAL
PRODUCT: - AIR HANDLING UNIT
Edgetech Air Systems Pvt. Ltd.

51/14, Swarn Park, Udyog Nagar, Mundka, Delhi-110041 Tel.:+91-11-28344270-72 Fax: +91-11-28344935
E Mail: Email: sales@edgetech.co.in Website: www.edgetech.co.in
OPERATION
PRE START-UP CHECKS
9 Place the equipment in its place and ensure that 1 meter minimum distance from the walls on
access door side for maintenance of all moving parts.
9 It is always possible for components to loosen during transport. It is therefore recommended

that the tightness of all bolts and screws be verified before startup (particularly moving parts
such as fans, pullies and bearings etc.)
9 Turn the fan wheel by hand to ensure that it turns freely and verify that no freely and verify
that no foreign bodies are lodged in the fan scroll.
9 Verify the lubrication fan and motor bearings ( see maintenance )
9 Check that there are no foreign bodies in the unit (or in the duct system) and that air inlets
and outlets are not blocked.
9 Check that all dampers are in their correct positions and that they operate correctly.
9 Check all electrical connections and check that the motor turns in the correct direction.
9 Ensure the motors are single phase / Three Phase.
9 Ensure electrical supply as per motors Specification.
9 Check the alignment and tension of the bolts and realign and re-tension if necessary (see
maintenance).
9 Cooling coil sections are fitted with condensate drains. Check that these are properly fitted to
allow draining and avoid air suction and water carry-over.

DELAYED STARTUP
If installation and start-up do not occur immediately after delivery, take the following precautions:
9 Protect the equipment in an area not exposed to excessive humidity.
9 Take special care to protect electrical components.
9 Periodically, manually turn all moving parts to avoid any possibility of blocking.
9 For long stocking periods, remove electrical equipment and store in a dry atmosphere.
9 Verify the motor lubrication before start-up and follow the motor manufacturers
recommendation ( see recommended oil )
9 It should be noted that the bearings are pre lubricated. It is however possible that start-ups
will be noisy until the grease is evenly distributed.
9 Check that electrical connections comply with the wiring diagram and that the thermal
protection is operational.
9 For units with variable air volume devices, check that the dampers are fully open.
9 Isolators: Check that the vibration isolators are free to operate and that no other contact
exists between the fan/motor chassis and the supports.
START-UP
9 After completing the checks in the above paragraphs the unit may be started and the
following checks and adjustments performed.
9 Measure motor voltage and amperes to ensure proper protections, compare reading with the
motor name plate.
9 Check fan air volume by measuring air volume and pressure. If the volume is incorrect it may
be modified (within the limits of the fan curve) by balancing dampers and/or by changing
pulleys of the effective diameter of variable pitch pulley.
Note: Airflow varies with fan speed, the pressure varying as a square function. The absorbed horsepower varies as
a cube of the above relationship. If the system pressure requirements are over-estimated the airflow will increase,
thus increasing the absorbed power and creating a risk of overloading the motor. The factor is much greater
important for forward curved type fans. For backward inclined fans the absorbed power curves are practically
parallel to the speed curves.

MAINTENANCE
GENERAL
The maintenance of air conditioning equipment should be carried out bearing in mind the basic
rules of personal security.
Ensure that:
1. The Engineer is electrically isolated from the unit ( by isolating board, rubber mats etc. )
2. The Engineer does not enter the unit before the fan has stopped turning.
3. The electrical equipment is correctly isolated from the main supply before entering the unit
(fan, electric coils etc.)
The majority of air handling units requires the same type of maintenance. The following
paragraphs describe basic service requirements.
The maintenance frequency will vary depending upon the cleanliness of the operating
environment and the operating schedule of the unit.
Before carrying out equipment maintenance it is worth remembering that in an air conditioning
installation, the fan is selected to give a particular airflow against a certain pressure. Any
element, which tends to change the operating point, such as dirty filters, dirty coils or blocked air
grills, will tend to cause poor operation of the installation since it will work at other than the
design conditions.

MAINTENANCE
The procedures listed here should be completed every 3-6months. The frequency of their
completion will depend on load and ambient conditions. Procedures detailed after this list give
more information on suggested conditions and schedules.
1. Check all fan bearings for signs of wear and / or grease leakage. Lubricate the fan bearings (
if not sealed for life time).
2. Check bearing locking setscrews and other setscrews for proper tightness. All bearing races
must be secure.
3. Lubricate fan motors.
4. Align pulleys and check level of shafts
5. Check fan belt tension. Adjust if belt slips. Replace worn or frayed belts with a new
matched set. Do not force belts onto pulleys.
The following should be completed once a year:
1. Inspect electrical wiring for condition. Tighten all connections.
2. Inspect the unit casing and accessories for chipping or corrosion. If damage is found, clean
and repaint.
3. Clean fan wheels and shaft. Remove rust from fan shaft with an emery cloth, and re coat the
shaft with a suitable varnish.
For external units, check all access door seals are in good condition and replace if necessary.
Adjust the hinges to take up any looseness.

MAINTENANCE FOR EVAPORATIVE COOLING WET SECTION
Warning: Before doing any maintenance be sure to disconnect from power source. This is for
your safety.
Spring Start-Up
Cleaning Pads: A clean pad is more absorbent, efficient and will give more cool air. Annually, or
when required, using a garden hose with nozzle, back wash to clean out the openings, then
clean off the inlet face any scale or other obstruction to the passages. Slight scraping may be
required to remove hardened scale.
Pad Replacement: The pads should be replaced after 5 years or if necessary. To change pads,
remove side access panel, disconnect water delivery tube. Remove water distributor holder and
lift out media sections. Replace with the same type media.
Cleaning Pump: Cleaning the pump is necessary once with in 3 months at start-up. For your
safety, disconnect from power source and unplug pump. Remove the pump from the mount
bracket. Remove the base of the pump. Clean the pump and turn the impeller to ensure free
operation. After cleaning, reinstall the base onto the pump. Reattach the pump to the mount in
the cooler to ensure that the pump will not overturn. Do not forget to replace the spout and water
delivery tube onto the pump outlet. Pump will operate normal again after obstruction is cleared.
Drain Water: Always drain all of the water out of the cooler and water supply line when not in
use for prolonged periods, and particularly at the end of the season. Keep the water line
disconnected from both the unit and water supply so that it does not freeze.
Disconnect form power supply when not in use for extended periods of time.
Cover Unit: To protect the life of the finish, a cover for the unit is suggested in extended periods
of non use.
By following the operating, installation, and maintenance suggestions as outlined, you can get
many years of efficient and satisfactory service from your cooler. In the event additional
information is desired, your dealer will be more than glad to assist you in every possible way.

BEARING LUBRICATION
Fan bearing of imported fan are pre greased and sealed for life. Operating temperature range
from -30°C to 85°C.
BELT TENSIONING
It is important that belts are maintained at the correct tension to avoid premature bearing failure
and unnecessary belt wear. There are two methods of checking belt tension.
a. The increase in belt length when it is stretched can be measured. The increase under
tension should be from 0.6% for a small unit with continuous running, to 1.0% for large
units with irregular motor torque.
b. Using a proprietary instrument such as the browning belt tension checker.
BELT MAINTENANCE
Clean fan belts and pulleys with a dry cloth. Oil and grease must be kept off belts. The use of a
belt dressing is not recommended. When replacing belts, use a matched set. Do not force belts
onto pulleys, but adjust motor position to allow mounting and then re-tighten.
PULLEY ALIGNMENT
This is checked by means of a straight edge, which should touch both edges of both pulleys at
the same time.
COIL SECTIONS
Periodic checking of coil cleanliness is required. Dirty coils increase airside pressure drops and
reduce heat transfer potential, thus unbalancing the complete system.
An effective means of coil cleaning is by jet of air, steam or hot/cold water applied in the opposite
direction to normal airflow. For very dirty coils, a detergent may be added to the jet.
Caution: Do not use hot water or steam for cleaning direct expansion coils.
In the event that fin edges have been bent flat, these can be straightened with the aid of a “ Coil
Comb”.

RECOMMENDATIONS FOR HOT OR CHILLED WATER OR STEAM COILS
It is strongly recommended to employ correct water treatment as proposed by a specialist, after

analysis of the water. This treatment should avoid fouling at the coil tubes and loss of
performance.
FILTER SECTIONS
The frequency of filter service is difficult to define since it depends upon the atmospheric
pollution and filter type. The maximum interval should be 10-15 days for pre and 20-25 days for
microvee filters.
During system start-up, filters are likely to become rapidly blocked due to the dust etc. in the
system ducts.
Disposable filters and bag filters are normally replaced each time that the pressure drop reaches
its predetermined limit. Limited cleaning by agitation or vacuum is possible. Permanent
synthetic or metallic filters (pre filter & microvee filter) may be cleaned periodically. These
cleanable filters should be initially shaken and tapped followed by blowing through with
compressed air (pressure max. 5 Kg/cm) in the opposite direction to normal airflow. Panels may
then be washed in luke-arm bath containing a detergent (Teepol type). They should then be
rinsed in fresh water before drying. Please ensure full removal of detergent by repeated water.
Do not remove media from frame for washing. Refix the filters when properly dried.
Dampers
No particular maintenance is necessary.
Note: Filters must be installed following the direction of the airflow arrow. Note
that the support grill should be on the air outlet side of the panel.
SAFETY WARNING FOR ELECTRICAL MOTORS
RECEIVING
Each shipment should be carefully inspected upon arrival. Any damage should be reported
promptly to the carrier and a claim filed.

STORAGE
If the machine will not be put into service immediately, certain precautions should be taken to
protect the machine while in storage. It is recommended that the machine be placed under cover
in a clean, dry location.
During storage, windings should be protected from excessive moisture by some safe and reliable
method of heating, such as space heaters, to keep the temperature of the windings a few
degrees above the temperature of the surrounding air. It is recommended that the machine be
inspected at periodic intervals, the windings meggered, and a log kept of pertinent data. Any
significant drop in insulation resistance should be investigated.
Precautions are taken by the factory to guard against corrosion. The machined parts are coated
to prevent rust during shipment. If the equipment is to be stored, examine the parts carefully for
rust and moisture and re-coat where necessary.
Grease-lubricated machines have the bearings greased at the factory with the cavity
approximately 50% full.
Rotate the shaft of all two-bearing machine 10-20 revolutions at two month intervals.
HANDLING
Lifting lugs or eyebolts on the motor are designed for handling the motor only. They are not to be
used to lift the motor plus additional equipment such as pumps, or other driven equipment. In the
case of assemblies on a common base, lugs or eyebolt provide on the motor are not to be used
to lift the assembly and base. The assembly should be lifted by a sling around the base or by
other lifting means provided on the base. In the case of unbalanced loads (such as couplings or
other attachments) additional slings or other effective means should be used to prevent tipping.
Failure to observe these precautions may result in damage to the equipment, injury to personnel,
or both.
INSTALLATION
Coupling, belt and wire guards installed should not be removed to protect against accidental
contact with moving parts. Failure to observe these precautions may result in injury to personnel
Motor and control wiring, overload protection and grounding should be in accordance with the
national Electrical code and consistent with sound local practices. Failure to observe these
precautions may result in damage to the equipment, injury to personnel, or both.
Refer the electrical wiring diagrams (Fig. 1-1 & 1-2) for the motors and tables 1.1 & 1.2 for
choosing the correct cable, overload relays and fuses.

TROUBLE SHOOTING CHART FOR ELECTRICAL MOTORS
Affected parts Difficulty What to check

Windings Overheating • Calibration of measuring instruction
• Excessive current
• Unbalanced Ac current
• Improper or rested ventilation
• Excessive ambient temperature
• Short circuited coil or windings
• Dirty winding
• Unbalanced voltage
Bearing overheating • Calibration of measuring instruction
• Rough journal
• Misalignment
• Shaft currents
• Excessive or insufficient grease
• Worn out or dirty grease
Motor Excessive Vibration • Unbalance
• Misalignment
• Improper or settled foundation
• Non-uniform air gap
• Rubbing parts
• Bent shaft
• Unbalanced stator current
• Damaged bearing
Insulation Low Insulation • Moisture, dirty, metal practical, oil, or other
Resistance Or contaminants on the insulation windings
Insulation Failure
• Wrong voltage
• Excessive temperature
• Voltage surges
• Mechanical damage
• Excessive vibration with resultant
mechanical damage

Figure – 1-1

Figure – 1-2
DOL Wiring Diagram

Power Control
Note: 1. For 230 V supply X will be

connected to X1
2. For 440 V supply X will be connected to
X2

Table – 1.1
READY RECKONER FOR DIRECT-ON-LINE STARTING OF 3-PHASE INDUCTION MOTORS

415V, 50 HZ
FULL LOAD OVERLOAD RECOMMENDED RECOMMENDED

MOTOR RECOMMENDED
CURRENT RELAY SIZE OF COPPER SWITCHGEAR
RATING HRC FUSE
(APPROX) RANGE CONDUCTOR RATING
A
A A (SQ.MM.) A
HP KW
0.25 0.19 0.7 2 0.5 - 1 1.5 16
0.50 0.37 1.2 4 1-2 1.5 16
0.75 0.55 1.6 4 1-2 1.5 16
1.0 0.75 1.8 6 1-2 1.5 16
1.5 1.1 2.5 6 1.5 - 3 1.5 16
2.0 1.5 3.4 10 2-4 2.5 16
3.0 2.2 4.8 16 3-6 2.5 16
4.0 3.0 6.5 16 4-8 2.5 16
5.0 3.75 7.5 16 4-8 2.5 32
7.5 5.5 11.5 25 6 - 12 2.5 32
10.0 7.5 14.0 30 10 - 16 2.5 63
12.5 9.3 17.3 35 14 - 20 4.0 63
15.0 11.0 21.0 35 18 - 24 6.0 63
20.0 15.0 28.0 63 16 - 32 10.0 63
25.0 18.6 35.0 63 24 - 45 16.0 100
30.0 22.0 41.0 80 24-45 16.0 100
Note: The above table is based on the following assumption:
Max. Starting current – 6 x FLC. and max. starting time – 5 second. For values higher than assumed, larger fuse may be required.

Table – 1.2
READY RECKONER FOR STAR DELTA STARTING OF 3-PHASE INDUCTION MOTORS

415V, 50 HZ
RECOMMENDED
MOTOR FULL LOAD OVERLOAD RECOMMENDED
RECOMMENDED SIZE OF COPPER
RATING CURRENT RELAY SWITCHGEAR
HRC FUSE CONDUCTOR
(APPROX) RANGE RATING
(SQ.MM.)
HP KW
7.5 5.5 11.5 20 6-12 2.5 32
10.0 7.5 14.0 20 10-16 2.5 32
12.5 9.3 17.3 25 14-20 4.0 63
15.0 11.0 21.0 25 18-24 6.0 63
20.0 15.0 28.0 35 16-32 10.0 63
25.0 18.6 35.0 50 24-45 16.0 63
30.0 22.0 41.0 50 24-45 16.0 100
40.0 30.0 55.0 63 32-63 16.0 100
45.0 33.5 62.0 63 32-63 25.0 200
50.0 37.0 69.0 80 50-90 25.0 200
60.0 45.0 83.0 100 50-90 35.0 200
70.0 53.0 97.0 100 70-110 25.0 200
90.0 67.5 123.0 160 90-135 50.0 250
100.0 75.0 136.0 160 120-155 50.0 250
125.0 90.0 165.0 200 140-170 75.0 300
Note: The above table is based on the following assumption:
Max. Starting current – 2 x FLC. and max. starting time – 15 second. For values higher than assumed, larger fuse may be required.

MAINTENANCE SCHEDULE FOR AIR HANDLING UNITS
1. GENERAL SERVICE AND CHECKS
a. Lubrication frequency. As per manufactures instructions (for fan and motor bearings).
b. Filter replacement frequency. As per filter loading as specified.
c. Belt change frequency. As required but not less than every three (3) months.
2. DAILY SERVICE AND CHECKS
a. Check and record steam pressure to heating coil.

b. Check and record water temperatures entering and leaving cooling coil.
c. Check and record water temperatures entering and leaving cooling coil.
d. Inspect filter sections for air bypassing filters.
e. Check that drain pans and drains are clean.
f. Check bearing temperatures.
g. Check motor rotation.
h. Check motor temperatures.
i. Check Motor Starters.
j. Check controls for proper operation.
3. MONTHLY SERVICE AND CHECKS
a. Repeat all daily checks, recordings and inspections.

b. Check, adjust and clean outside air intake, outside air intake louvers, screens, outside air-
motorized dampers and re-circulating air-motorized dampers.
c. Check damper blades for tight closing (outdoor air intake).

d. Check piping appurtenances: steam traps, air vents, drains and strainers; check piping for
leaks, check for damaged insulation.
e. Clean all heating and cooling coils.
f. Check fan bearing alignments.
g. Check fan bearing for wear and tear.
h. Clean fan section and fan wheel.
i. Clean unit casings, plenums and connecting duct.
j. Check that motor electrical connections are tight, check for arcing of brushes and check that
motor shaft / sheave is secure.
k. Check that all motor started connections are tight and clean all contacts.
l. Automatic temperature control systems: inspect, check, clean, adjust, repair and calibrate all
control devices, interlocks, electric-pneumatic (EP) and pneumatic-electric (PE) switches,
compressors and refrigerated air dryers.
4. YEARLY SERVICE AND CHECKS
a. Repeat all daily and monthly checks, recordings and inspections.

b. Check louvers, dampers, filter frames, coils, casings, plenums and fans for corrosion. Clean
and treat as recommended by the manufacturer.
c. Check coil and fan for corrosion, wear and tear.
d. Check fan shaft as per manufacturer’s recommendations.
e. Check fan shaft for straightness that the fan wheels are tightly fastened to the shaft and the
drive sheaves are secured.
f. Clean motor frame and air passages.
g. Check motor acceleration time, voltage, current and speed.
h. Check motor anchor bolts and vibration isolation.

i. Motor Starter: clean and check contacts, clean housing, check for proper operation and
overload protection.
j. Duct work: check for dust, moisture, defective linings, defective insulation and leaks.
k. Mechanical insulation: check and repair all damaged pipe insulation, fitting insulation, valve
insulation, duct insulation, casing a housing insulation.
PLEASE NOTE
In any case of abnormal operation, stop the fan and check the cause. Early detection can avoid
much more serious fan damage.
These operation and maintenance instructions are given as a guide to good practice for
operation, service and periodic maintenance by the user / owner of Edgetech Air Systems Pvt
Ltd. It does not contain the full service procedures necessary for the continued successful
operation of Air Handling Units. The services of a qualified service technician / contractor should
be employed for the same.


Operation Manual of AHU

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Operation Manual of AHU

Загружено:

Авторское право:

Доступные форматы

OPERATIONS

PRODUCT: - AIR HANDLING UNIT

Edgetech Air Systems Pvt. Ltd.

PRE START-UP CHECKS

9 It is always possible for components to loosen during transport. It is therefore recommended

9 Verify the lubrication fan and motor bearings ( see maintenance )

9 Ensure the motors are single phase / Three Phase.

9 Ensure electrical supply as per motors Specification.

Edgetech Air Systems Pvt. Ltd.

9 Protect the equipment in an area not exposed to excessive humidity.

9 Take special care to protect electrical components.

Edgetech Air Systems Pvt. Ltd.

Edgetech Air Systems Pvt. Ltd.

3. Lubricate fan motors.

4. Align pulleys and check level of shafts

The following should be completed once a year:

1. Inspect electrical wiring for condition. Tighten all connections.

Edgetech Air Systems Pvt. Ltd.

Edgetech Air Systems Pvt. Ltd.

b. Using a proprietary instrument such as the browning belt tension checker.

Edgetech Air Systems Pvt. Ltd.

It is strongly recommended to employ correct water treatment as proposed by a specialist, after

No particular maintenance is necessary.

SAFETY WARNING FOR ELECTRICAL MOTORS

Edgetech Air Systems Pvt. Ltd.

Edgetech Air Systems Pvt. Ltd.

Affected parts Difficulty What to check

Edgetech Air Systems Pvt. Ltd.

Edgetech Air Systems Pvt. Ltd.

DOL Wiring Diagram

Note: 1. For 230 V supply X will be

Edgetech Air Systems Pvt. Ltd.

READY RECKONER FOR DIRECT-ON-LINE STARTING OF 3-PHASE INDUCTION MOTORS

FULL LOAD OVERLOAD RECOMMENDED RECOMMENDED

Edgetech Air Systems Pvt. Ltd.

READY RECKONER FOR STAR DELTA STARTING OF 3-PHASE INDUCTION MOTORS

Edgetech Air Systems Pvt. Ltd.

1. GENERAL SERVICE AND CHECKS

2. DAILY SERVICE AND CHECKS

a. Check and record steam pressure to heating coil.

3. MONTHLY SERVICE AND CHECKS

a. Repeat all daily checks, recordings and inspections.

Edgetech Air Systems Pvt. Ltd.

4. YEARLY SERVICE AND CHECKS

a. Repeat all daily and monthly checks, recordings and inspections.

Edgetech Air Systems Pvt. Ltd.

Edgetech Air Systems Pvt. Ltd.

Вам также может понравиться