MAINTENANCE
GENERAL REQUIREMENTS
The maintenance requirements for AHUs
are shown below. The procedure is in the
left-hand column, and the minimum
required frequency is marked is described
in the right-hand column.
Refer to ANSI/ASHRAE Standard 62.1-
2010 for startup and maintenance practices
related to achieving acceptable indoor air
quality.
This documented program for regular
publication of including procedures for
timely, documented, consensus action on
requests for change to any part of the
standard.
STANDARD OPERATIONAL
PROCEDURES
All maintenance and repair process
implemented according to prescribed
procedures and SOPs :
Always coordinative with the leadership
in order to generate jobs as efficiently as
possible,
The scheduled maintenance, schedule
equipment and inspection equipment
specifications prepared so effective as
needed.
Completeness of materials that will be
used: materials cleaning fluid, cleaning
cloth; if necessary, air compressor,
inspected and sorted according to the
treatment procedure.
disassembly tools and measuring
devices needed examined in order to work
properly and safely
MAINTENANCE PLAN
The following table ( see Table 1) gives
recommended maintenance intervals for
the air handling unit. Intervals are base
upon normal running conditions, in a
moderate climate, and assuming 24 hour
running. Units operating outside these
guideline may require shorter or longer
maintenance intervals.
The maintenance interval periods are
stated, guidelines only. Any large
deviations in the pattern of usage may
necessitate further maintenance attention.
WARNING
Disconnect electrical power and
allow rotating parts to stop before
servicing the unit. Exercise caution if
unit must be on for test or
maintenance procedures. Failure to
do so may result in injury or death
from electrical shock or moving part
WARNING
Disconnect electrical power prior to
access into fan or ductwork. Even
when locked out electrically, fans
may cause injury or damage if the
impeller is subject to "windmilling".
The impeller should be secured to
physically restrict rotational
movement can cause severe personal
injury or death.
PERIODIC MAINTENANCE
Checklist The following checklist
describes the suggested maintenance
schedule to maintain proper operation of
the unit. Detailed procedures for
owneroperator maintenance checks are
given after this checklist
After 48 Hours Operation
Fan and Direct drive Motor their
permanent tight. Readjust if not but dont
overtighten.
Weekly
Observe unit weekly for any change in
running condition and any unusual noise.
Every Month Or Weekly
Check air filters. Clean or replace if
clogged or dirty. Change bag filters when
pressure drop is till final resistance value.
Check damper linkages, set-screws and
blade adjustment for proper damper
operation.
lnspect the control and power box wiring
for secure connections and insulation.
Rotate the fan wheel and check for
obstruction in the fan housing. The wheel
should not rub on the fan housing. Adjust
the center if necessary and tighten wheel
setscrews to the proper torque.
Check condition of gasketing and
insulation around unit, door and damper.
Examine flex connections for cracks or
leaks. Repair or replace damage material.
MAINTENANCE PLAN
The following table (see Table 1) gives
recommended maintenance intervals for
the air handling unit. Intervals are base
upon normal running conditions, in a
moderate climate, and assuming 24 hour
running.

Every Three to Six Months Units operating outside these guideline

may require shorter or longer maintenance
Check pulley on fan and motor. intervals.
Tighten electrical connection.
lnspect coils for dirt build-up or coil
freeze up

Every Year

lnspect the unit casing for corrosion. lf

damage is found, clean and repaint the
surface with a rust-resistant primer and
vinyl chlorinated lacquer.
Clean the fan wheels and fan shaft.
Remove rust with emery cloth and apply a
coat of LPS#3 or an equivalent.
lnspect the condensate drain pan and
drain line, remove sludge or foreign
materials that might obstruct proper
drainage. Remove obstacles.
Tabel 1 - Recommended Maintenance Intervals

36
Component Check the following Weekly Mounthly Annual
Mounthly
Fan in general
Connection
Fan and Pulley fan
Motor
Motor in general
Pulley motor
Clean/ replace Pre filter
Check the medium filter
Clean/ replace medium
Filter
filter*
Check the Hepa filter
Clean/ replace Hepa filter*
Visually inspect coils for
cleanliness and microbial
growth.
Coil Fin block/fin bundle
Frost
Drainage
Heater
Heater
Wiring
Damper Damper
Hood fresh air
Inlet/outlet
Louver
Piping drain
drainage
Drain pans
quantity of Aiflow
outdoor air Microbial contamination*
in the AHUs
Control box and wiring
Control
Sensor

*Minimum frequencies may be increased or decreased from what is indicated in this table.
INSPECT PARTS
Inspect the following parts for damage,
dirt and debris.
Cabinet
Clean the exterior of the AHU with a mild,
environmental safe detergent and high-
pressure water at 2000 psi.
Door Hardware
Inspect the doors, handles, latches and
hinges for proper operation, and the door
for damage and if they are properly sealed.
Secure any loose parts.
Panels Inspect
the panels for damage. If the panels show
signs of excessive pressure change, they
will appear to bulge inward or outward.
Refer to Troubleshooting on page 78
regarding excessive static pressure. If the
panel needs to be replaced, use the
instructions later in this section.
Hoods And Louvers
Inspect the air hoods and louvers for
damage and debris. Remove debris as
needed.
Fan
If Unit not daily operation Fan motors
must be operated for at least 2 hours every
month to prevent possible fan set failure.
The fan infrequently to dirty because
material fan is C-pro of Alumunium .
Check for soiling, damage, corrosion, and
any tendency to bind. Clean as necessary.
Check that the flexible connection are
securely fixed. Check the function of all
antivibration mounts.
Check for any obstructions or blockages
of the air intakes and discharges.
Check the traps for leaks or blockages and
prime as necessary.
If using EC fans, it is possible to reverse
these using the designated input signal to
the fan set (view unit specific wiring
diagram). The fans will operate as per the
0 10 V input signal. To move as much
debris as possible, it is advisable to run the
fans at the maximum speed the application
noise level will allow. For what this
voltage will be, with respect to the unit
noise level please contact us for
representative. The fans do not need to
operate in reverse for longer than 2
minutes to move large debris and some
lightly applied particles on the fin surface.
Heavier fouling must be removed using a
pressure water/steam jet washer (Max
pressure 3bar) against direction of airflow,
at a distance of 300 to 400mm using a
neutral cleaning agent if required. The
spray should be even across the coil face
and as with a brush, applied in a
longitudinal direction across the fins.
Motor
lnspect periodically for excessive vibration
or temperature. Operating conditions will
vary the frequency of inspection and
lubrication.
Dirty motor run hot when thick dirt
insulates the frame and clogs cooling
air passages. ( motor exterior should be
periodically cleaned to remove
contaminants that can affect heat
dissipation from the motor.
Check for signs of corrosion.
Lubricate the bearings only when
scheduled or if they are noisy or
running heat. Do not overl lubricate.
Excessive grease and oil captures dirt
and can damage bearing.
Feel the motor frame and bearing for
excessive heat or vibration. Listen for
abnormal noise that may indicate a
potential motor failure. Promptly
identity and eliminate the source of the
heat, noise or vibration.
Verify that belt and motor drive guards
are securely fastened so as not to cause
vibration and noise and possible damage
to equipment and personnel.
Motor protection is PTC thermistor
temperature sensors are predominantly
used for thermistor motor protection
devices (alarm or shutdown) for motors.
These thermistors are generally integrated
in the winding overhang. As a
consequence, the stator windingis directly
protected. The temperature difference
between alarm and shutdown (trip) is 10K.
When a limit temperature is reached
(nominal trippingtemperature), the
resistance of PTC thermistors will have a
step change. This is evaluated by
atrippinunit and can be sued to open
auxiliary circuits
Dirty motors run hot when thick dirt
insulates the frame and clogs cooling air
passages. Motor exterior should be
periodically cleaned to remove
contaminants that can affect heat
dissipation from the motor.
Check for signs of corrosion : Lubricate
the bearings only when scheduled or if they
are noisy or running hot. Do not over-
lubricate. Excessive grease and oil captures
dirt and can damage bearings.
Feel the motor frame and bearings for
excessive heat or vibration. Listen for
abnormal noise that may indicate a
potential motor failure. Promptly identify
and eliminate the source of the heat, noise,
or vibration.
Air Filters
Every month, check the cleanliness of the
filters, and if necessary, replace them.
Filters should be replaced when the
pressure drop, measured by a manometer,
reaches the prescribed limits for the
installation.
Filter types pre filter, medium filter and
HEPA filter are the typical filter types as
shown in Figure. If your AHU has HEPA
filters, the filter frames, bulkheads and
segment panels are factory sealed, and
must remain sealed for NO air bypass.
Fig.1 Prefilter
Fig.2 Medium filter
Fig.3 Hepa filter
1. Check filter sizes anquantities. Refer to
the filter label located oneach filter
segment.
2. Remove filter frame end cover as shown
in Figure 66 on page 66and Figure 67 on
page 66.
3. Remove old filters, if present.
4. Make sure gaskets at both ends of the
side load filter tracks are in place.The
gaskets are normally found on inside of
filter frame end covers.
5. Slide the correct size new filters into
tracks.
7. Airflow arrows must point downstream
(in direction ofthe airflow).
8.Install all pleated filters with pleats
positioned vertically.
9.Reinstall the filter frame end cover.
To clean permanent filters wash under a
stream of water to remove dirt and lint.
Remove oil filter (aluminum or grease
filter) with a wash of mild alkali solution.
Rinse in clean, hot water and allow to dry.
Coat both sides of the filter by immersing
or spraying it with Air Maze Filter Lote W
or equivalent. Allow to drain and dry for
about 12 hours.
Coil Segment Cleaning
Coils, whether for heating, cooling, or
dehumidifying, should be clean both
internally and externally, and the fins for
heat transfer should be intact and
undamaged.
Typically, coils (especially cooling coils)
are externally cleaned once a year, as this
side of the coil receives the most dirt (from
the air stream).
Coils may be periodically pressure tested
for leaks.
Control valves wear out over time due to
constant modulation. These valves should
be included in a regularly scheduled
maintenance program.
By treating heating steam and heat transfer
water, tubes of coils should remain clean,
and heat transfer capability should remain
high for a number of years.
Steam, hot water and chilled water coils
should be kept clean to maintain maximum
performance. lf fins become dirty, clean
with steam and detergent, hot water spray
and detergent, or one of the commercially
available chemical coil cleaners. Rinse
coils throughly after cleaning.
Direct expansion coils
Never use hot water or steam to clean these
coils. During normal opeartion, the fin
block must not ice up. If this occurs, check
the refrigeration system.

If cleaning coil by periodically, clean dirty

coil with water and detergent because just
dust and mildew on coil, but if coil have
slag slould clean with chemical cleanser.

WARNING
Follow all directions provided with
chemical cleaners to avoid personal
injury and/or coil damage.
Commercially available chemical
cleaners may contain caustic or
hazardous agents For direct expansion coils, do not use hot
water or steam to clean these coils. During
normal operation, the fin block must not be
In the event of coils being out of ice up. If this occurs, check the
commission for some time, it is advisable refrigeration system. Check that drain pan
to completely drain down the coil. On each and drain trap are free from blockage and
occasion when refilling is undertaken, water accumulation at pan.
check that the coil is effectively vented.
Refrigerant coils should be kept clean to
Periodic cleaning of the coils is required. maintain maximum performance. If fins
Dirty coils have increased airside pressure become dirty, clean with cold water and
drops and reduced heat transfer,thus detergent or one of the commercially
unbalancing the cooling or heating system. available chemicals coil cleaners. Rinse
coils thoroughly after cleaning
Cleaning In the event that fin edges have
been bent, they can be straightened with
the aid of a coil comb. WARNING
Never use steam or hot water to
The cleaning is carried out with the unit
clean a refrigerant coil. Dangerous
intact using a powerful vacuum cleaner on
the dust-contamainated side. If the unit is pressures may be built up by
very dirty it will need to be removed and improper application of heat
wet cleaned. resulting in equipment damage oe
personal injury.
If required, soft cleaning brushes may be
used ensuring that the heat exchanger fin
are not damaged.
Damper

Prior to occupancy, test ventilation system

to ensure that outdoor air dampers operate
properly in accordance with the system
design.

Check for dirt accumulation, damage and

sign of corrosion. Clean with cloth or high
pressure air. Check damper blade turning
manually or central control for smooth
operation.

Cleaning procedure Cleaning of dampers

should be performed before operation is
hindered in any way. Maintenance
personnel must determine when cleaning is
necessary based on observation and
operation.

Electric Heater

Check for dirt accumulation and clean if

necessary with a soft brush. Check the
safety control, cables and connections
operation.

Heat Wheel & Heat Pipe

The unit should be maintained in line with

the manufacturer recommendation.
 TROUBLE SHOOTING
Use the table 5 to assist in trouble-shoot the malfunction in Air Handling Unit operation.

Table 5 Trouble Shooting Analysis

Symptom Probable Cause Recommended Action

Motor Fail Start a) Blown fuse or open circuit a) Replace fuse or reset circuit
breaker breaker.
b) Improper wiring. b) Check wiring with diagram
supplied.
c) Mechanical Failure. c) Check motor & drive rotate
freely & bearing lubricant.
Motor overheats a) Overloaded motor a) Reduce load or replace larger
motor.
b) Motor Fan dirty/ damage. b) Clean/ replace motor fan.
Fan does work a) No Power Supply / power a) Check Power supply
Failure
b) Fan capacitor faulty b) Change switch
c) Fan motor faulty c) Operate when power supply
resume
d) Switch faulty d) Replace motor fan / clean
e) Start trip e) Contact Local dealer
f) Fuse blown in power switch or
operating unit
Low air volume after a) Fan rotating in wrong direction.a) Reverse any two phase
start up connection at motor terminal.
b) Air damper not properly set. b) Ensure system correctly
balance & set.
c) Pressure drop by filter above c) Change filters (complete
recommended level. bank).
d) Motor fan is clogged with dirt d) Remove fan cover, clean fan
preventing proper ventilation and replace cover
e) Reduce load or replace with
larger motor
Air Conditioner works a) thermostat setting too high a) Rest Thermostat
but cooling not
b) Doors and/or windows not b) Close doors and/or windows
satisfactory closed
c) Condenser coil dirty c) Contact local dealer
d) Some objects blocking the inlet d). Remove the object
and/or outlet of the unit
e) Indufficient refrigerant charge e) contact local dealer
Note: The table is intended as a diagnostic aid.
Symptom Probable Cause
Water present in cooling a) Drain trap clog.
coil drain pan or b) Incorrect hydraulic trapping
overflow
Filter collapsing a) Filter block with dirt.
b) Air velocity too high.
Damper seizing Blade bent
Spindle or mechanism loose
Actuator loose
Low coil capacity Air is by passing coil
(Chilled Water)
Coil tubes are blocked
Incorrect airflow (CFM)
Incorrect water flow rate (GPM)
Incorrect water temperature
Low coil capacity Air is by passing coil
(Refrigerant)
Coil tubes are blocked
Incorrect airflow
Expansion valve not operating
Poor refrigerant distribution
Leaking Coil Header / exposed pipe damage
Cracks in joints due to strain of
pipework on headers
Swelling of joints due to frost
(Water-hammer Steam Coils)
Drain pan overflow Incorrect hydraulic trapping
Blockage in trap
Plugged Drain Line
Unit not level
Wet interior insulation Coil face velcity too high
Improper trap design
Drain pan leaks / overflows
Condensation on surfaces
Note: The table is intended as a diagnostic aid.
Recommended Action
a) Clean & clear clog.
b) Resize trap and check air break
arrangement
a) Replace at advised dirty
condition.
b) Check unit running conditions.
Repair or replace blade
Tighting lever fixings
Refit actuator correctly
Prevent bypass with block-off
Clean and unblock tubes
Check water pumps, valves and
lines for obstructions
Provide proper water temperature
Prevent bypassing with block-off
Clean and unblock tubes
Check fan-operating conditions
Check sensing bulb location and
TXV operation
Check for blockage in distributor
and tube
Repair damaged part
Check support and alignment of
pipework and rectify
Check frost protection method
and correct, improve Trapping of
steaam supply
Resize / fit trap and check air
break arrangement
Clean trap and refit
Clean drain line
Level unit
Reduce fan speed
Design trap per unit installation
instructions
Repair leaks
Insulate surfaces