TC Manual Air Handlers

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Temperature Control Manual Version 0.1

Date: 1/02/2007
Air Handler Prepared By: Justin Day
Engineering Department
Temperature Control Manual
AIR HANDLERS
TC Manual Air Handlers.doc Aggreko Australia Pacific

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Date: 1/02/2007
TABLE OF CONTENTS
Section Page
1 INTRODUCTION................................................................................................................ 3
1.1 Description........................................................................................................................ 3
1.2 Equipment......................................................................................................................... 3
1.2.1 Air Handler Enclosure ................................................................................................. 3
1.2.2 Fan ............................................................................................................................... 4
1.2.3 Motor ........................................................................................................................... 4
1.2.4 Cooling Coil ................................................................................................................ 5
1.2.5 Control Panel ............................................................................................................... 5
1.2.6 Inlet Screen and Filters ................................................................................................ 5
1.2.7 Inlet and Outlet Cam-Lock Fittings............................................................................. 6
1.2.8 Outlet Spigots .............................................................................................................. 6
1.3 Applications...................................................................................................................... 6
2 TECHNICAL DATA ........................................................................................................... 7
3 INSTALLATION, OPERATION AND MAINTENANCE (IOM) ............................... 18
3.1 Introduction..................................................................................................................... 18
3.2 Installation ...................................................................................................................... 18
3.2.1 Location ..................................................................................................................... 18
3.2.2 Foundation ................................................................................................................. 18
3.2.3 Duct Connections ...................................................................................................... 18
3.2.4 Suction and Discharge Hose...................................................................................... 18
3.3 Commissioning ............................................................................................................... 18
3.3.1 Commissioning Checks ............................................................................................. 18
3.3.2 Priming ...................................................................................................................... 19
3.3.3 Starting the Unit......................................................................................................... 19
3.4 Operation ........................................................................................................................ 19
3.4.1 Operational Checks.................................................................................................... 20
3.4.2 Principal of Operation ............................................................................................... 20
3.5 Decommissioning ........................................................................................................... 21
3.6 Maintenance Procedures ................................................................................................. 21
3.6.1 General Maintenance ................................................................................................. 21
3.6.2 Bearing Lubrication ................................................................................................... 21
3.6.3 Belt Tensioning.......................................................................................................... 22
3.6.4 Belt Maintenance ....................................................................................................... 22
3.6.5 Pulley Alignment....................................................................................................... 22
3.6.6 Coil Sections.............................................................................................................. 22
3.6.7 Service Requirements for the Air Handler ................................................................ 23
3.6.8 Maintenance Schedules ............................................................................................. 23
4 ELECTRICAL ................................................................................................................... 28

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Date: 1/02/2007
1 INTRODUCTION
1.1 Description
Aggreko’s package air handling units are used for a wide variety of applications,
including , but not limited to; comfort air conditioning of temporary outdoor facilities for
public events, supplementary comfort cooling of building rooms and spaces, removal of
excessive heat and moisture from heavy industrial working inclosures, supplementary
cooling of industrial processes involving heat and heat transfer, underground mine shaft
cooling and dehumidification, storage space cooling for increasing product shelf life, and
spot cooling for specific industrial heat relief applications.
A typical air handler is a pre-fabricated unit and consists of a number of components such
as; an air intake louver, panel type filters, a bank of chilled water cooling coils, a
centrifugal fan, electric motor, belt and pulley drive set, an air discharge plenum chute,
discharge spigots (connection for 500mm flex ducting), which is all contained in a
thermally and acoustically insulated enclosure.
The chilled water is generated by an external fluid chiller, which is circulated through the
air handler’s coils by the use of an external fluid pump; this is all connected with flexible
hose’s by the use of cam-lock fittings.
1.2 Equipment
1.2.1 Air Handler Enclosure
All moving components are enclosed in a prefabricated, sheet metal enclosure that is
acoustically lined to ensure low level noise.

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1.2.2 Fan
The fan is of a centrifugal type consisting of Backward Curved Laminar Blades

constructed from galvanised steel.
a. Shaft: Constructed from C40 carbon steel, coated with an anti-corrosion varnish
after assembly;
b. Bearings: All bearing are either deep groove ball or spherical roller bearings type
sealed both sides;
i. Deep groove ball bearings are self-aligning with an eccentric locking collar
for clamping onto the shaft.
ii. The bearings are lubricated for life and maintenance free. If re-lubrication is
necessary, it is recommended to use a lithium base grease suitable for all
temperatures within the operational limits
1.2.3 Motor
The motor is a 415Volt, 3 phase, 50 Hertz, 4 pole unit with a nominal rpm of 1440.

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Date: 1/02/2007
1.2.4 Cooling Coil
The cooling coil varies between the 3 types of Air Handlers. Each one is constructed of a
copper coils with aluminium fins. Coils range from 6 to 8 rows in depth. The coil pictured
is out of a 300Kw unit, 8 rows deep.
1.2.5 Control Panel
The control panel is constructed from Stainless Steel and houses the start, stop and
controlling devices for the air handler. Further information will be provided in Section 4
of this manual.
1.2.6 Inlet Screen and Filters
The inlet screens are usually constructed of aluminium with the filter elements located
either at the front or rear of those screens. The filters are a removable cartridge V-form
type. The type of filters may change depending on the application.

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Date: 1/02/2007
1.2.7 Inlet and Outlet Cam-Lock Fittings
The inlet and outlet fittings on the Air Handlers are a 100mm (4”) or 50mm (2”) NATO
cam-lock fitting.
1.2.8 Outlet Spigots
Discharge Outlets are 500mm in diameter and accommodate either our Mine Flat or Mine
Flex duct work. Reduction in size is discouraged due to the extra load this will place on
the fan.
1.3 Applications
Aggreko’s package air handling units are used for a wide variety of applications including
but not limited to; comfort air conditioning of temporary outdoor facilities for public
events, supplementary comfort cooling of building rooms and spaces, removal of
excessive heat and moisture from heavy industrial working inclosures, supplementary
cooling of industrial processes involving heat and heat transfer, underground mine shaft
dehumidification and cooling, storage space cooling for increasing product shelf life, spot
cooling for specific industrial heat relief applications.
Pictured above is a couple of 100Kw Air Handlers that are being utilised in conjunction
with some of Aggreko’s other units for marque cooling.

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Date: 1/02/2007
2 TECHNICAL DATA
aggreko
Prepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 7 of 28
Discipline: Air Handlers Document number
Section:
INDUSTRIAL RANGE AHC100A Au2.2
1. INTRODUCTION
The Characteristics of an air handler is a cold water coil through which air is transported.
The cold water coil is fed by a water chiller unit by means of rubber hoses. The processed air is
transported through 500 mm air duct.
A high performance fan provide sufficient amount of static pressure to distribute the processed air via
temporary ducting systems.
2. KEY-DATA
Design Capacity Cooling 112 kW at 30°C, Rh 50%, Fluid Temperature 6°C

Heating 190 kW
Air Volume 10800 ³/hr
Electrical Fan rating 9.4 kVA
Dimensions length 1.81 metres
width 1.06 metres
height 2.37 metres
weight 770 kg
3. LAY-OUT

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4. TECHNICAL SPECIFICATIONS
ITEM UNITS VALUE

Performance Data Cooling
Design Cooling Capacity kW 116

Design Sensible Cooling Capacity kW 68
(1
Heating Capacity with Warm Water kW 190
Design Air Inlet Temperature °C / RH% 30 / 50
Design Air Outlet Temperature °C / RH% 11.3 / 95
Condensation Water Substraction at Design Condition g/s 21.6
Water Side
Design Water Inlet Temperature °C 6

Design Water Return Temperature °C 15.2
Maximum Inlet Water Temperature °C 55
Design Water Flow l/s 3
Design Pressure Drop kPA 13.5
Maximum Water Pressure kPA 100
Fluid Volume
Air Side
Design Air Volume m³/s 3.0

Maximum External Pressure at Design Flow Pa 1200
Minimum Air Volume at Free Outlet m³/s 1.0
Maximum Air Volume at Free Outlet m³/s 5.0
Fan Type Centrifugal Backward Curve
Fan Speed Rpm Variable 500 to 2500
Air Volume Control Variable Speed Drive
Number of Air Outlets 500mm 1
Electrical Data
Design Electrical Supply Voltage Volts 415

Design Electrical Rating kVA 9.4
Nominal Current A 13
Starting Current A 13
Cable Connection 32A Clipsal 3ph earth and neutral
Noise Data
Sound Pressure Level at 10 mtr Lp(A) dB(A) 54

Sound Power Level Lw(A) dB(A) 82
Physical Data
Overall Length metres 1.80

Overall Width metres 1.06
Overall Height metres 2.37
Weight kg 770
Fluid Connections mm / inch 50mm / 2” Camlock
NOTE: Contact Technical Department If Application Conditions Differs from Design Conditions
1)
Heating Capacity at design flow, air on temp. 0°C, air off temp. 55°C, water temperature 60°C.

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Aggreko AH100 Performance

350
300
Humidity 90%
250
70
50
30
Capacity kW
200
10
150
100
50
10 15 20 25 30 35 40
Air On C
Based upon 60 water temperature

3
3 m /s air flow
3 l/s water flow

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Date: 1/02/2007
aggreko
Prepared by: Adam Hentschel Date: 07.02.2002 Revision: A Page 10 of 28
Section:
INDUSTRIAL RANGE AAH300A au2.1
1. INTRODUCTION
Acoustic lining and air inlet louvres ensure low noise levels. A high performance fan provide sufficient
amount of static pressure to distribute the processed air via temporary ducting systems.
2. KEY-DATA

Heating 751 kW
Air Volume 6.85 m³/s
Electrical Fan rating 25 / 11 kVA
width 2.44 metres
height 2.75 metres
weight 2200 kg
3. LAY-OUT

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ITEM UNITS VALUE

Design Cooling Capacity kW 300

Design Sensible Cooling Capacity kW 173
(1
Design Air Outlet Temperature °C / RH% 10 / 96
Performance Data Heating
Design Capacity kW 715

Temperature Rise at Design Flow Condition °C 30
Maximum Outlet Temperature °C 100
Water Side
Design Water Inlet Temperature °C 6.0

Design Water Flow l/s 15.0
Design Pressure Drop kPA 88.4
Fluid Volume
Air Side

Minimum Air Volume at Free Outlet m³/s 0
Fan Type Backward Curve Centrifugal
Fan Speed Rpm 1240 / 1862
Air Volume Control Inlet guide vanes, 4 pole / 6 pole,
Outlet opposed blade dampers
Electrical Data
Design Electrical Supply Voltage Volts 415

Design Electrical Rating kVA 25.2 / 10.8
Nominal Current A 35 / 15
Starting Current A 210 / 108
Cable Connection 40A Clipsal
Noise Data

Physical Data

Weight kg 2200
Fluid Connections mm / inch 100 / 4"
1)
Heating Capacity at design flow, air on temp. 0°C, air off temp. +55°C, water temperature 60°C .

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900
Aggreko AH300 Performance
800
700
Humidity 90%
70
600
50
30
Capacity kW
500 10
400
300
200
100
10 15 20 25 30 35 40
Air On C
Based upon
15 l/s water flow
3
7.2 m /s air flow
6o C entering water temperature

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Date: 1/02/2007
aggreko
Prepared by: Jason Dignam Date: 05.09.2005 Revision: A Page 1 of 3
Section:
INDUSTRIAL RANGE AH300 W au2.4
1. INTRODUCTION
transported through 3 x 500 mm air ducts.
Acoustic lining and air inlet louvres ensure low noise levels. A high performance fan provides sufficient
amount of static pressure to distribute the processed air via temporary ducting systems.
This unit can also be fitted with an electric heater that is capable of supplying 90kW of heating to the
air stream.
2. KEY-DATA

Heating 90 kW Electric Heating
Air Volume 6.85 m³/s
Electrical Fan rating 21.8 kVA
Dimensions Length 2.90 metres
Width 2.3 metres
Height 1.96 metres (without lobster backs)
Height 2.74 meters (with loster backs)
Weight 1600 kg (without heating elements)
Weight 1680 kg (with heating elements)
3. LAY-OUT

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ITEM UNITS VALUE

Design Cooling Capacity kW 304.8

Design Sensible Cooling Capacity kW 173.8
(1
Design Air Outlet Temperature °C / RH% 9.2/ 98
Design Capacity (water) kW 715

Electric Heating (when fitted) kW 90
Water Side
Design Water Inlet Temperature °C 6.0

Design Water Flow l/s 15.0
Design Pressure Drop kPA 70
Fluid Volume Litres 85
Air Side

Minimum Air Volume at Free Outlet m³/s 0
Fan Speed Rpm Variable up to 1600
Air Volume Control Variable speed drive to motor
Pressure Drop pa 287
Electrical Data
Design Electrical Supply Voltage Volts 380 - 415

Design Electrical Rating kVA 21.8
Nominal Current A 33
Starting Current A 33
Cable Connection 40A Clipsal
Noise Data

Physical Data

Weight kg 1600 (no elements)
Weight kg 1680 (elements)
1)
Heating Capacity at design flow, air on temp. 0°C, air off temp. +55°C, water temperature 60°C .

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Date: 1/02/2007
Based upon
15 l/s water flow
7.2 m3/s air flow
6o C entering water temperature

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Date: 1/02/2007
aggreko
Prepared by: Graham Blixt Date: 11/09/2003 Revision: A Page 1 of 28
Section:
INDUSTRIAL RANGE 421/390 kW au.2.3
1. INTRODUCTION
Acoustic lining and air inlet louvres ensure low noise levels. A high performance fan provide
sufficient amount of static pressure to distribute the processed air via temporary ducting systems.
2. KEY-DATA
Design Capacity, 460v 60Hz Cooling 421kW at 35°C, Rh 50%, Fluid Temperature 7.2°C
415v 50Hz Cooling 390kW at 35°C, Rh 50%, Fluid Temperature 7°C
Heating XXX kW
Air Volume 8.5/ 6.8 m³/s
Electrical Fan rating 29.5/ 26.6 kVA
width 2.52 metres
height 2.6 metres
weight 2608 kg
3. LAY-OUT

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4. SPECIFICATION
ITEM UNITS VALUE

Performance Data Cooling 460v/60Hz 415v/50Hz
Design Cooling Capacity kW 421 390

Design Sensible Cooling Capacity kW xxx 198
(1)
Heating Capacity with Warm Water kW xxx xxx
Design Air Inlet Temperature °C / RH% 35 / 50 35/50
Design Air Outlet Temperature °C / RH% 13.5 / 96 11.65/96
Condensation Water Substraction at Design Condition g/s 86 78
Design Capacity kW 715

Water Side
Design Water Inlet Temperature °C 7

Design Water Flow l/s 18
Design Pressure Drop kPA 152
Maximum Water Pressure kPA XXXX
Fluid Volume
Air Side
Design Air Volume m³/s 8.5 6.8

Maximum External Pressure at Design Flow Pa 996 700
Minimum Air Volume at Free Outlet m³/s 0 0
Maximum Air Volume at Free Outlet m³/s 10.8 8.97
(2)
Fan Speed Rpm 2048 1700
Air Volume Control
Electrical Data
Design Electrical Supply Voltage Volts 460 415

Design Electrical Rating kW/kVA 23.5/29.5 21.2/26.6
Nominal Current A 37 37
Starting Current A 222 222
Cable Connection
Noise Data
Sound Pressure Level at 10 mtr Lp(A) dB(A) XX
Sound Power Level Lw(A) dB(A) XX
Physical Data

Weight kg 2608
1) Heating Capacity at design flow, air on temp. 0°C, air off temp. +55°C, water temperature 60°C
2) A pulley change is required to achieve higher fan speeds at 50Hz, this may cause motor overloading.

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3 INSTALLATION, OPERATION AND MAINTENANCE (IOM)
3.1 Introduction
Proper installation of our Air Handlers will assist greatly in their ability to perform to
their optimum capability. As with all of Aggreko’s units, the ground must be compact
and level, priming of hose’s and units are to be carried out IAW (in accordance with)
procedures laid down in this manual. Failure to carry out these procedures will lessen the
working life and dramatically reduce the efficiency of the Air Handler.
3.2 Installation
3.2.1 Location
The Air Handler should be located in a dry and well ventilated area. The Air Handlers
should be as close to the Fluid Chillers/ Air Conditioning Units as possible. This will
reduce the heat loss through the hoses, allowing maximum heat transfer through the Air
Handler coil.
3.2.2 Foundation
A solid foundation is required for the positioning of the unit. A suitable level base, be it
concrete, compacted gravel or soil should be sought.
3.2.3 Duct Connections
Ducts should be designed as a function of the fan orientation. Sudden changes in duct
cross section or use of bends close to the fan discharge should be avoided.
3.2.4 Suction and Discharge Hose
All pipe work must be free from air leaks and should be short as possible. This will
reduce the effects of cavitation. Proper priming procedures should be followed. This will
be covered in Section 2.3.1 Priming.
3.3 Commissioning
Prior to an Air Handler being brought on line, the cooling coil and associated piping
should be flushed out, where possible. This is to reduce the risk of cross contamination
between jobs.
3.3.1 Commissioning Checks

a. Complete thorough cleaning of cooling coil.
b. Check operation of supply fan/s.
c. Replace air filters.
d. Inspect and grease bearings as required.
e. Check control panel wiring.
f. Check starter panel wiring.
g. Check safety switches and interlocks.

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h. Check parameters of control modules.

i. Inspect condition of contactors.
j. Confirm contactor action.
k. Confirm contactor overload settings.
l. Flush through and clean drain pan.
m. Complete full wash down of unit.
n. Check drive belt tension.
3.3.2 Priming
Priming of the Air Handlers should be conducted in conjunction priming the Fluid
Pumps.
a. Once all the hose’s are connected, open all vent cocks whilst filling, to expel
trapped air in the water system.
b. Once system has been filled, pressurize system and check for leaks.
3.3.3 Starting the Unit
Prior to starting the unit, the following pre-start checks are required to be carried out;
a. Inspect coils and outlet for debris (especially units that have endured long road
trips);
b. With power isolated, check fan and motor rotate freely;
c. Check that discharge outlet dampers are open;
d. Ensure drain pan is clean and free from any debris that may block the draining of
condensate;
e. Check drive belts for tension;
f. Ensure that drive belt guard is secured if fitted (if no guard is fitted, log on job
commissioning report);
g. Open all fluid valves;
h. Ensure Fluid Pump (if fitted) is up to required pressure; and
i. Power-up Air Handler.
Once all pre-start checks have been completed, the unit may now be started.
3.4 Operation
The centrifugal fan inside the air handler unit draws in outdoor or outdoor/return air
through the filter bank and the cooling coils. During this process, both the sensible and
latent heats are removed by the cooling coils to a predictable/ approximate extent. This
result's in reduction of energy contained by the air flow and therefore changes in
properties of air, simply known to as ‘cooling and dehumidification’.

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Cooled and dehumidified air is then discharged to the process or use point by the fan with
certain static pressure performance characteristics to overcome the internal resistance
created by the air intake louver, air filter bank, cooling coils, discharge fittings, etc., as
integral and internal parts of the air handler. Additionally, the fan is designed to
overcome some external system resistance created by supply air duct work, duct fittings,
air diffusers, process application system, etc.
Fan motor speed and therefore fan speed is controlled by a built-in programmable VSD
(Variable Speed Drive) or mechanical drive pulley system. As fan speed is directly
proportional to air flow rate, the flow and cooling requirements of a particular application
can be achieved accurately to the pre-engineered project-specific estimations.
3.4.1 Operational Checks
Once the unit is in operation, it is important to carry out the following checks;
a. With power applied to the unit, measure the motor voltage and amps to ensure
proper protection, compare readings with the motor nameplate;
b. Check fan air volume, by measuring air volume and pressure;
c. Continue with bleeding off the cooling coils. Isolate vent cocks when there is a
steady stream of water and no air exist in the system;
d. Listen for abnormal noise and visually inspect (from a safe distance) fan and motor
for correct operation;
e. Check for leaks around the coil;
f. If the Air Handler is fitted with protection devices, test for correct operation;
3.4.2 Principal of Operation

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3.5 Decommissioning
The decommissioning procedure is as follows:

a. Push Stop Button and allow unit to wind down.
b. Electrically isolate Air Handler.
c. Ensure fluid pump has been shut-down prior to isolating the inlet and outlet cooling
coil valves on the Air Handler.
d. Remove hose’s to and from unit. If possible drain water from a point away from the
Air Handler.
3.6 Maintenance Procedures
3.6.1 General Maintenance
The procedures listed here should be completed every 3-6 months. 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.
a. Check all fan bearings for signs of wear and tear and/or grease leakage.
b. Check bearing locking setscrews and other setscrews for proper tightness. All
bearing races must be secure.
c. Lubricate fan motors.
d. Align pullies and check level of shafts.
e. Check fan belt tension. Adjust if belt slips. Replace worn or frayed belts with a new
matched set. Do not force belts onto pullies.
The following should be completed annually.
a. Inspect electrical wiring for condition and tightness.

b. Inspect the unit casing for chipping or corrosion. If damage is found, clean and
repaint.
c. Clean fan wheels and shaft. Remove rust from shaft with a fine emery cloth, and
recoat the shaft with a suitable varnish.
For external units, check all access door seals are in good working condition and replace
if necessary. Adjust the hinges to take up any looseness.
3.6.2 Bearing Lubrication
Fan bearings with grease fittings or with grease line extensions should be lubricated with
a lithium base grease which conforms to N.L.G.I. number 2 for consistency and which is
free of chemical impurities.
Improper lubrication can result in premature failure of the bearing. To lubricate the fan
bearing, complete the following;
a. Bearings are to be lubricated while the unit is NOT running.
b. Disconnect main power supply.

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c. Connect a manual grease gun to the grease line or fitting.

d. Add grease, preferably when bearing is warm, until a light bead of grease appears
at the bearing grease seal while turning the fan wheel manually.
CAUTION: Do not over-lubricate the bearings. Excessive pressure caused by over

lubrication can displace bearing grease seals or cause grease to overheat the bearing,
resulting in premature bearing failure.
Use only the grease recommended for the type of bearings mounted on CLCH unit, the
following types can be used;
a. Alvania Grease 3 (Shell).
b. Mobilux 3 (Mobile Oil)
c. Beacon 3 (Esso)
d. SKF 28 Ball bearing grease.
3.6.3 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 for belt tension.
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 continuos running, to 0.1% for large
units with irregular motor torque.
Use a proprietary instrument such as the browning belt tension checker.
3.6.4 Belt Maintenance
Clean fan belts and pullies with a dry cloth. Oil and grease must be kept off of belts. The
use of a belt dressing is not recommended. When replacing belts use a matched set. Do
not force belts onto pullies, but adjust motor position to allow mounting and the re-
tighten.
3.6.5 Pulley Alignment
This is checked by the means of a straight edge, which should touch both edges of both
pullies at the same time.
3.6.6 Coil Sections
Periodic checking of coil cleanliness is required. Dirty coils increase air side pressure
drops and reduce heat transfer potential, thus unbalancing the complete system.
An effective means of coils cleaning is by a jet of air (LP Air), steam or hot/cold water
applied in the opposite direction of normal airflow. For very dirty coils, a detergent may
be added to the jet.
In the event that fin edges have been bent flat, these can be straightened with the aid of a
‘coil fin comb’
CAUTION: Do not use hot water of steam for cleaning direct expansion (DX) coils.

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3.6.7 Service Requirements for the Air Handler
The service for the Air Handler is an ‘A’ service. This is to be conducted every three (3)
calendar months (where possible) and on return to depot after hire.
Before commencing a service, complete a review of the most recent service report for any
abnormalities or defects.
CAUTION – Ensure the Air Handler is isolated from its electrical supply before
commencing with the shutdown inspections. A Danger Tag should be fitted to all
machinery that work is being conducted on.
3.6.8 Maintenance Schedules
The following are the Maintenance Schedules for the Aggreko Air Handlers:

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Maintenance Schedule for Aggreko's Air Handlers AH100 and AH300:

Completion
Monthly 6-Monthly
Item On Hire and of Hiring
Maintenance and Servicing Instructions Installation
or at 750 or at 4300
and
No. Hours Hours
Decomm.
General Structure and Containment of Air Handlers:

1 Carry out overall inspection. X X X
2 Dry out moisture from air handler. Vacuum and clean all compartments and coils. X
3 Switch on, check manual controls as applicable. X X X
4 Check panels, service access doors, and fastening for leaks. Repair leaks. X X
5 Replace any defective lights inside air handler. X X X
6 Inspect flexible connections and repair as necessary, as applicable. X X
7 Check and tighten anti vibration pads. X X
Clean, lubricate and prove operation of all air dampers, as applicable to the system
8 X X
set-up.
9 Ensure casing insulation is secure. Repair as necessary. X
10 Inspect the casing for corrosion and leaks. Repair as necessary X
11 Remove corrosion, repair paintwork. X
Chilled Water Cooling Coils:

1 Examine coil to ensure internal sections are not blocked X X
2 Inspect condensate drain trays, ensure drains are clear, trays are clean. X X X
3 Check for leaks on coils and piping connections. X X X
4 Check control valves for internal leaks. Repair leaks. X X X
5 Vent cooling coils X X
6 Check temperature across coil, adjust as necessary. Record results. X X
7 Inspect coils for dirt built-up and clean as necessary X X X
8 Inspect coils for fin damage and comb if necessary. X
Inspect CHW buffer (feed & expansion) tank, piping, and fittings. Repair leaks as
9 X X
necessary.
Fan and Belt Drive System:
1 Test the operation of the fan. X X X
2 Check and report fan for vibration, bearing noise or overheating. X X
3 Ensure free rotation of the fan. X X
4 Check correct rotational direction of the fan. X
5 Check that impeller and drive pulleys are tight on shafts. X X X
6 Check pulley alignment. Align and tighten pulleys. X X X
7 Check groove wear on pulleys. Replace worn-out pulleys as necessary. X
8 Check for wear on motor-fan belts. Replace as necessary. X X
Check and adjust motor-fan belt tension. Ensure on multi-belt drive belts have the
9 X X
same tension.
10 Spray or coat belts with a commercial compound to reduce pulley slip. X X
11 Check belt guard firmly in place. X X X
Check manual mechanism for adjusting fan inlet guide vanes (to control supply air
12 flow rate) and ensure the moving parts are intact and operational for adjustment, as X X
applicable to some air handlers.
Clean and lubricate the bushes, linkages, and spindles of the manual inlet guide
13 vane adjustment mechanism to manufacturer's recommendations, as necessary, as X
applicable to some air handlers.
14 Check and tighten mounts and holding down bolts for secure operation. X X
15 Inspect and repair flexible duct connections, as necessary, as applicable. X X
16 Clean impeller, casing, and peripheral components as necessary. X
16 Lightly lubricate the fan shaft bearings to manufacturer's recommendations. X X
17 Clean fan blades and the scroll fan casing. X
18 Remove corrosion, repair paintwork and lightly grease bright steel. X

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Completion
Monthly 6-Monthly
and
No. Hours Hours
Decomm.
19 Check access panels for air leakage. Repair and seal leaks. X
Electric Motor:
1 Check Motor bearings for any noise and over-heating. X X
Lightly lubricate motor bearings to manufacturer's recommendations. Do not use

2 excessive greasing. The electric motor data is included in Section ___ of this IOM X
Manual.
3 Check all connections and associated wiring X X
Check maximum duty current (Amps.) against the motor nameplate. Record any
4 X X
motor overload. Expedite causes of motor overload.
Megger test the motor, preferably when it is cold. Check Voltage balance of the
5 X
phases.
6 Test proper functioning of the field isolator by the electric motor, as applicable.
Remove, strip, and clean motor, clean bearings, and repack or replace as After 60 months of
7 operation
necessary.
Flexible Ductwork, Duct Fittings, and Air Distribution Systems:

1 Check for air leaks [audible or observed]. X X
Check for rain seepage into external or internal ductwork. Drain seepage and repair
2 X
as necessary.
3 Inspect all flexible connections for tears, delamination or loose connections. X X
4 Inspect ductwork for any physical damage. X X
5 Observe for undue noise, whistling or rattles. X X
6 Inspect components for UV damage. X X
7 Inspect insulation and examine for loss of vapour seal and deterioration. X X
Measure air flow rates at air outlets to ensure intended design conditions. Record
8 X X
results.
Where air flow rates are low, check fan, filters, cooling coils, volume control
9 X X
dampers, and collapsed internal insulation. Correct and adjust.
10 Inspect and clean air outlets, outdoor air intake louvers, and dampers, as applicable. X X
11 Inspect duct hangers for support and security. X X
Electric Duct Heaters:

(self-contained modular portable optional units intended to be installed at supply air discharge side of air handler for reheat 'trim'
controlling of space relative humidity):
Check and ensure that the self contained unitary electrical duct heater is equipped
with safety features such as: automatic high temp. power cut-off thermostat limit
1 switch, air pressure switch, thermal overload protection switch, electronic controller, X X
safety warning instructions (affixed onto the unit), and the as-built electrical power
and control diagram.
Inspect interiors of the electric heating unit, and ensure that no rubbish or
2 X X X
combustible material is present.
Test high limit thermostat and ensure that the electric heaters turn off. Check
3 X X
settings on the controller.
4 Switch off the fan, ensure that all electric heating elements do switch off.
5 Check all electrical connections for soundness and tightness. X X
Inspect electric heating elements for combustible rubbish, dust and electrical
6 X X X
operation.
7 Test individual elements and record current drawn. X
Dry Media Air Filters:

Use a magnehelic manometer to take static pressure differential pressure across the
1 dry media filter bank. Replace the filters if the static resistance exceeds 125 X
Pascal’s.
2 Discard the disposable filters and clean washable filters, as applicable. X

Page 26 of 28

Date: 1/02/2007
Completion
Monthly 6-Monthly
and
No. Hours Hours
Decomm.
3 Order new filters or filter media if required for next service. X X
4 Check the zero setting on the magnehelic manometer.

Check for air leakage around the filters, ensure that filter media edge is seated
5 X X
properly in the channel provided.
Vacuum clean filter chamber and inlet screens after each filter change and at the
6 X X
time of decommissioning..
7 Ensure that media is not disintegrating or delaminating. X
8 Check operation of door safety interlocks, as applicable. X X
9 Examine the filter bank grid for any broken wires. Repair as necessary. X X
10 Clean outdoor air intake louver blades, channels and frame. X X
Electrical System:
Ensure that a safety warning sign with the safe power isolation and reconnection
1 X X X
procedures are affixed next to the control panel (MCCB) as legible and easily visible.
Check and ensure that the electrical circuit diagram of the air handler is provided in
2 a document holder pocket inside the control panel along with the maintenance and X X
service log book.
Before, during, and after any electrical inspection or servicing works specified
herewith on the control panel and the associated electrical system, strictly follow the
3 X X X
safety warning instructions and the safe power isolation and reconnection
procedures.
4 Check control panel switchgear and instrumentation for possible physical damage. X X
5 Switch on the air handler and ensure that all components are operational. X X X
On the control panel, check for any sign of burnt-out spots, hot connections and
6 X X
burnt-out contacts on starters and relays. Clean, tighten and rectify.
On the control panel, replace any faulty switches, fuses, contactors, relays, as
7 X X
necessary.
8 On the control panel, check all fuses for correct rating. X X
On the control panel, examine the seals on external switches, push buttons,
9 X X X
conduits, and cable penetrations for any damage. Repair and replace as necessary.
On the control panel, check functioning of indicator lights and replace any faulty
10 X X X
indicators.
11 Check overload rating against motor nameplate rating. X X
Check the soundness, tightness, and physical condition of the flexible conduits, rigid
12 conduits, incoming power cabling, field wiring, lugs, connectors, wiring terminals, X X
and connection boxes. Repair and replace as necessary.
Inspect insulation on incoming power supply cabling and field wiring. Repair any
13 X X
damaged portions. Strictly follow power isolation and reconnection procedures.
14 Replace any labels that have fallen off or been removed. X X
Report any discrepancies between the electrical wiring diagram and the actual
15 X X
electrical system of the air handler.
16 Lubricate all pivot points. Use pure petroleum jelly. X
Control Systems:
Check and record temperature and relative humidity in air conditioned space or
1 zones. Adjust/ reset thermostat and humidistat operating set points, as necessary X X
and as applicable.
Heat the space temperature sensor with a hair dryer something similar and ensure
2 X X
correct temperature sensing response.
Check the space/ zone temperature sensor position, and ensure that it is not
3 partitioned out of the area it controls or affected by local heaters, equipment or other X X
air conditioning systems.

Page 27 of 28

Date: 1/02/2007
Completion
Monthly 6-Monthly
and
No. Hours Hours
Decomm.
Install a thermograph interfaced with the electronic temperature controller, and

4 record and monitor the actual conditions against the design intent. Resolve any X X
irregularities by attendance to air handler operation.
Program the fan motor VSD (Variable Speed Drive) to deliver the intended design
5 X X
supply air flow rate. Monitor the performance.
Monitor and inspect the VSD for any failure to start-up or overheating or failure to
6 operate to the programmed parameters. Refer to the diagnostics and trouble- X X
shooting guide list in VSD user manual to rectify the problems.
Install a pitot tube station for pressure measurements, and calculation and
7 X X
monitoring of supply air flow rate to the specified design parameters.

Page 28 of 28

Date: 1/02/2007
4 ELECTRICAL
TECO Speecon 7200GA/MA
The following instructions are provided by the manufacturer ‘TECO’ on their controllers
that have been fitted to Aggreko’s Air Handler Units.

TC Manual Air Handlers

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Page 1 of 28

Temperature Control Manual Version 0.1

Temperature Control Manual