GEWAN ISLAND
District Cooling Plant
Title: Training Session for
Air Handling Units and Fan Coil units
Project : Gewan Island District Cooling Plant
Client: Qatar Cool
Consultant: Dar Al Handasah
MEP Contractor: Bluestar Qatar
Supplier: FJ Trading & Engineering WLL
Equipment: Air Handling Unit / Fan Coil Unit
Manufacturer: Euroclima (Italy)
Course Title: HVAC System – Air Handling Units
and Fan Coil Units
Purpose: To provide an overview training for the
equipment technical specifications, Operation and
Maintenance as per Manufacturer’s
recommendation.
PRESENTATION OUTLINE
Introduction
Module 1 – Air Handling Unit Description
Module 2 – Fan Coil Unit Description
Module 3 – Preventive and Corrective
Maintenance
Module 4 – Troubleshooting
Module 5 – Manufacturer’s Contact details
(Technical and After Sales Service support
Module 1
Air Handling Unit Description
SCHEDULE OF EQUIPMENT
AHU = 15 nos.
AHU CONFIGURATION
A
B
C
D
TYPE 1 Unit (DCP-AHU-1, Dwg.01) (Qty: 2 nos.)
A. Mixing Box (with FA & RA dampers)
B. Prefilter and Bag Filter
C. Cooling coil
D. Fan / Motor
AHU CONFIGURATION
A
B
C
TYPE 2 Unit (Qty: 4 nos.)
DCP-AHU-2, Dwg.02; DCP-FAHU-02, Dwg.06
A. Prefilter and Bag Filter
B. Cooling coil
C. Fan / Motor
AHU CONFIGURATION
D
A
B
C
TYPE 3 Unit (DCP-AHU-3, Dwg.03) (Qty: 7 nos.)
A. Prefilter and Bag Filter
B. Cooling coil
C. Turning section
D. Fan / Motor
AHU CONFIGURATION
A
B
C
TYPE 4 Unit (DCP-AHU-4, Dwg.04) (Qty: 2 nos.)
(Outdoor Installation)
A. Prefilter and Bag Filter
B. Cooling coil
C. Fan / Motor
AHU CONFIGURATION
A
B
C
D
TYPE 5 Unit (DCP-FAHU-1, Dwg.05) (Qty: 2 nos.)
(Outdoor Installation)
A. Prefilter and Bag Filter
B. Heat pipe Precool
C. Cooling coil
D. Heat pipe Reheat
E. Fan / Motor
E
AIR HANDLING UNITS:
UNIT COMPONENTS and
DESCRIPTION
AIR HANDLING UNITS
UNIT CASING
ZHK 2000 S SERIES
- Double skin panels (Internal
panel – Galvanized 1.0mm /
External panel Galvanized
0.7mm both with White
preplastic coating)
- Assembled with self supporting
panel elements
- Thermal and acoustic insulation
(50mm thick with fibreglass
50kg/cu.m density)
COMPONENTS
-
Prefilter
Bag Filter
Cooling Coil
Heat pipes
Fan / Motor
AIR FILTRATION
FILTRATION
Pre-Filters
General Filter
CFW40-048
Class G4
Galvanized filter frame
with synthetic media
(cleanable)
Bag Filters
Camfil Standard Flo F7
Class F7
(soft bag type)
Galvanized filter frame
with synthetic media
(cleanable)
* ... Filter class as per EN779
HEAT
RECOVERY
HEAT
EXCHANGER
COOLING COIL (Chilled Water)
Material:
Tubes – Copper
Fins – Aluminium
Header – Copper
Frame – Galvanized steel
Drain Pan – Stainless Steel with
asphaltic coating
Drip Elimintors – PPTV with
Galvanized steel casing
Herasite coating for corrosion
protection
HEAT EXCHANGER
HEAT PIPE (with Refrigerant)
Materials:
Tubes – Copper
Fins – Aluminium
Header – Copper
Frame – Galvanized Steel
Refrigerant: R134a
Herasite coating for corrosion
protection
SUPPLY FANS
DIRECT DRIVE TYPE (PLUG FANS)
Fan Make: COMEFRI
Series: NPL/NPA model (backward
curved / airfoil impeller)
Motor Make: SIMOTOP / TECHTOP
Type: TEFC enclosure, IP55 protection,
Class F insulation, 4/2 pole
(1500/3000RPM), connected to Variable
Frequency Drive (VFD) control panel,
suitable for 400V/3Ph/50Hz (±5%)
electrical connection
Module 2
Fan Coil Unit Description
SCHEDULE OF EQUIPMENT
FCU = 36 nos.
Fan Coil Unit – Models & Qty
(Insert FCU model/location
schedule)
Module 3
Preventive and Corrective Maintenance
MAINTENANCE PLAN FOR EUROCLIMA AHU
Euroclima suggest
maintenance intervals which
are based on experience
under normal running
condition. (see Maintenance
Chart)
Note: Widely different
operating conditions,
particularly in respect of air
temperature humidity and
dust pollution will
considerably shorten the
maintenance interval
MAINTENANCE
Preventive Maintenance
The objective of preventive maintenance is to maximize the equipment
performance, availability and safety as it should function properly. A well planned
preventive maintenance program will ensure:

Good equipment performance and availability.

Consistent high level of safety for the users.

Minimal costs associated with breakdown.

General maintenance instructions for the equipment components require
preventive maintenance on a regular basis and also specify what type of actions
are needed.

The inspection interval depends on the frequency of use, operating
environment, aging of the equipment and the functionality required in the
preset operating context.
MAINTENANCE PLAN FOR EUROCLIMA AHU
The following should be incorporated in a planned maintenance schedule to
ensure that the equipment is well maintained.
In all cases the various sections of the equipment should be examined, and
any defects logged for replacement/repair.
Maintenance operations of air handling units are relatively simple, but they
still require routine operations aimed to maintain their efficiency of all their
components and to avoid damages which would negatively affect their good
working order and people’s safety.
The interval of maintenance operations depends on the unit effective
operating conditions.
MAINTENANCE PLAN FOR EUROCLIMA AHU
MAINTENANCE CHART
System
General
Fan & Motor
Component
Door gasket
Fasteners tightness,
in general
Check for corrosion
Weekly
Monthly
3 Months 6 Months
Check / Maintain
●
Check
●
●
●
●
Check
Vibration Isolators
Check
Motor, in general
Clean / Maintain
Motor bearings
Clean / Maintain
●
Check current consumption
Fasteners tightness,
in general
Check
●
Check / Maintain
●
●
Heat exchanger, fins
Check / Clean /
Maintain
Replace
Check / Clean /
Maintain
Replace
Check / Clean
Frost protection
Check
Condensate tank, drain
Check / Clean
Droplet separator
Check / Clean
Filters
Bag Filters
Yearly
●
Flexible connection
Prefilters
Cooling Coil
Activity
Check
If necessary and properly maintained / at least twice a year
●
If necessary and properly maintained / at least once a year
●
●
●
●
Maintenance Chart for FCU
MAINTENANCE PLAN FOR EUROCLIMA AHU
GENERAL SAFETY PRECAUTIONS
General Safety Instructions
DANGER

It is the owner's responsibility to ensure that all maintenance personnel are
fully conversant with the safety instructions described by the equipment
manufacturer.

The purpose of this list of safety procedures is to provide general precaution
to be used by the personnel that will install, operate, or maintain the system
described within this manual.

This should not be used to replace instructions that are provided by the
equipment manufacturer; therefore, anyone attempting to work on any
equipment should be thoroughly familiar with the specific instructions for
that particular unit.
GENERAL SAFETY PRECAUTIONS
General Safety Instructions
Electric power connection / Circuit breaker / Grounding
Make sure that there is a main power switch. Before opening air handling unit,
it must be disconnected from electric power supply.
 Make sure that the unit is powered by a dedicated power supply. Other
equipment connected to the same power supply could cause an overload.
 The AHU must be properly grounded to avoid electric shock.
 If in exceptional cases motor runs while maintenance staffs are working inside
the AHU (for example while taking measurements), maintenance staff must
wear clinging clothes as there may be danger of being suck into the fan.
 Works are to be carried out with minimum two (2) persons.
1st Person: Person carrying out the maintenance
2nd Person: Person staying at the main power switch for disconnection from power
supply.

GENERAL SAFETY PRECAUTIONS
General Safety Instructions
Secure Inlet and outlet openings

All the inlet and outlet openings of AHUs must be properly connected to ducts
or respectively equipped with grilles to prevent effectively access from the
outside to moving parts (such as fan wheels) during operation
Risk of thin sheets when working on AHU

During working on AHU (or on parts), there is a substantial risk of cutting with
thin sheets (example roof sheets, fins of heat exchangers, corners and edges),
USE personal protective equipment: wear protective helmet, gloves, safety shoes
and long protective clothing.
GENERAL SAFETY PRECAUTIONS
General Safety Instructions
Lighting

Proper lighting should be provided when working on AHU (maintenance or
inspective work).
Exposure to rotating parts / hot surfaces / electrocution
When working on AHU note the following risks:
Indentation of body parts in moving parts (belt drive, fan impeller...)
Burns and scalds on hot AHU components such as heat registers, heat
exchangers.
Electrocution on current-carrying parts such as electric motors,
frequency converters, electric heaters, control cabinets, interior lighting
etc.
GENERAL SAFETY PRECAUTIONS
General Safety Instructions
Exposure to rotating parts / hot surfaces / electrocution



All current-carrying parts, such as fan motors, valves, motors and electric
heaters are disconnected from the power supply by using the main power switch
The housing of the AHU interior lighting (can have separate supply) is not
current-carrying.
All moving parts, especially fan wheel, motor and heat wheel have come to a
standstill; wait at least 2 minutes after switching off before opening the doors.

Remove the key from doors with door lock before entering in the casing of the
AHU. Keep the key out of reach of unauthorized persons.

Check that the hot media supply such as steam is interrupted and all the heat
registers, heat exchangers, etc. are cooled to ambient temperature.
GENERAL SAFETY PRECAUTIONS
Safety During Operation

Do not forcefully open the fan section when the unit is running. You could be
injured if you accidentally touch rotating, hot or high voltage parts.

Never block or insert fingers, sticks etc. into the intakes or outlets, otherwise
injury may result, since the fan inside the unit rotates at high speed.

If you detect odd smell, stop using the unit, turn off the power switch and
consult your dealer. Otherwise, a breakdown, electric shock or fire may result.

When you notice exceptionally abnormal noise or vibration, stop operation,
turn off the power switch, and contact your dealer.
In Case of Failure

If the air handling unit fails to start, there is an abnormality. Stop the operation
and contact your facility maintenance staff. Operating the unit under such
conditions may result in fire or permanent failure.
SYSTEM OPERATION
Start Up Procedures

Verify that fan is connected tightly to the motor shaft according to
manufacturer's recommendations.

Check AHU External is in good condition and no damage.

Check fan rotation and bearing operation.

Verify that bolts and nuts are tightened.

Check condensate drains for proper connections.

Check AHU is properly tagged.

Ensure air filters are in place.

Ensure motor wiring is secured and terminated as per manufacturer's
instructions.

Ensure motor earthing is completed.
SYSTEM OPERATION
WARNING
Do not touch the terminals during and immediately after the measurement as the
terminals are live.

The equipment are interface with the required start-up/stop controls, auto BMS
control.
The fan frame must be earthed furthermore, it must be verified that all its
components have the same potential.

The installer must connect the fan to the earthing circuit and check the
potential is effectively the same on all its components before starting the
machine.
SYSTEM OPERATION
After start-up the operations below must be carried out:

Check that the direction of rotation matches with the direction shown by the
arrow.

Check that the input current does not exceed the current shown on the product
identification label and/or motor nameplate. To have reliable information, allow
a reasonable period of stabilizing time. Avoid consecutive start-ups of the motor
as this would cause continuous overloads, and overheat the electrical parts.
Before start-up, allow enough time to cool down.

Check the bearing temperatures after the first hours of operation, as these are
the most critical. If necessary, stop the fan and restart it only after reaching the
ambient temperature. Then check that the temperature is lower than the
previously measured temperature.

Check no excessive vibration.

Check for unusual noise bearing noise.
MAINTENANCE
Introduction

The Air Handling Units have significant maintenance requirements. Follow the
instructions below to keep the equipment in good working condition.
DANGER

Disconnect and secure and locked to the “OFF” position all electrical power to
the air handling unit prior to inspection or servicing. Failure to comply with this
safety precaution could result in serious injury or death.

Dismantling and reassembling of the units and its components shall be
performed by the maintenance personnel or manufacturer maintenance
representatives.
FILTERS
Pre-Filters
Bag Filters
Filter Installation
Service & Maintenance
PANEL FILTERS
1. Dry panel air filters (cleanable). The contamination level of the filter can be
controlled by the differential pressure drop (check every 14 days to 1 month).
Reaching the pressure difference indicated in the technical data sheet,
cleaning or replacement is required.
2. Depending upon the condition of the filter, it must be cleaned or exchanged.
Cleaning:
•
Remove the dirty filter, shake, vacuum or blow out (air pressure not to exceed
5 bar). Filter media may be washed in warm water (maximum 35°C) using
traditional mild washing materials and finally thoroughly rinsing. Any grease
impregnated material should be soaked for approximately one hour in
washgrade alkali.
Service & Maintenance
Cleaning:

Do not wring filter media but allow them to drip dry thoroughly. As the
synthetic fibres dry quickly they can be re-inserted in a damp condition and
immediately put into use.

Clean the filter chamber before reinserting the filter Each frame mounted
filter cell must be fitted with 4 springs.

After filters have been cleaned 2 or 3 times the filter efficiency decreases and
so replacement of the filter is necessary.
Service & Maintenance
BAG FILTERS

Check the degree of filter soiling utilising differential pressure
measurement. If the pressure differential reading is high, cleaning or
replacement is necessary.

Take out the bag filter retaining the opening at the top (see sketch).
Transport of filter bags
Service & Maintenance
BAG FILTERS

Remove the dirty filter, vacuum or blow out (air pressure not to exceed 5
bar). Thereby, with the opening facing upwards direct a stream of water,
not too strong, into the filter and wash it out. The sediment must thus be
flushed out at the other end. Allow the cleaned bag filters to drip-dry,
they can be repositioned in a damp condition and brought immediately
into use. Before re-positioning, thoroughly clean the filter chamber and
check the filter and filter frame for air tightness.

In normal use bag filters likely need replacement following 2 or 3
cleaning cycles.

Each frame mounted filter cell must be fitted with 4 springs.

Bag filters should not be re-used and should be replaced when their
efficiency is depleted.
COOLING COILS
Coil Drain & Air Vent Connection
Service & Maintenance
MAINTENANCE:
1. Heat exchangers special maintenance is not required, only occasional cleaning
is recommended.
2. Depending on the hours of operation and filter maintenance approximately
every three months, the heat exchanger fins shall be check for dust
contamination, debris and cleaned if necessary.
3. The piping is to check for leaks. In case of leakage, kindly contact the
Euroclima Service Centre for rectification.
CLEANING:

The cleaning is carried out with the unit intact using a powerful vacuum
cleaner on the dust contaminated side. If the unit is very dirty it will need to
be removed and wet cleaned.
Service & Maintenance
CLEANING:

The coil may be cleaned with a steam jet or the segments washed
through with a powerful water jet and finally blown out with an air
line
clean here
Cleaning of coil

If required soft cleaning brushes may be used ensuring that the coil
fins are not damaged. In the event of fins being pressed in, relieve with
a thin blade / fin comb. Minor fin damage has little or no effect on coil
performance.
Service & Maintenance
CLEANING:

The fins of copper-aluminium heat exchangers are
particularly sensitive, therefore, use water with lowpressure for cleaning. Damaging the fins by mechanical
force leads to premature deterioration of the heat
exchanger.

Corrosion spots must be cleaned and protected with zinc dust paint.

Drain pan and drain should be checked for debris and cleaned, if
necessary.
Service & Maintenance
CLEANING:
Droplet eliminator:

Check droplet eliminator about once a year for contamination. Remove fins
and clean if necessary.

Contamination can cause damage by water drops and reduce the
performance of the device.

Please make sure that the fins are installed properly and are not bent.

Pollutants can cause poor performance of the AHU.
SUPPLY FANS
Service & Maintenance
MAINTENANCE:
FANS:
1. Check for dirt, debris, damage and corrosion, clean if necessary,.
2. Coat surface damage of the housing and impeller with zinc dust
paint.
3. Flexible connections are to be checked for damage/visual
inspection.
4. Check vibration isolators for proper mounting/damage
(visual inspections).
5. Check the protection grid for correct installation /damage (visual
inspection).
6. Test the fan impeller by rotating it by hand for abnormal noises.
Service & Maintenance
MAINTENANCE:
MOTOR

Check the motor for cleanliness and clean if necessary.

Measure current consumption which must not exceed the rated
current indicated on the nameplate.

Check motor bearings by rotating the shaft by hand and check with a
metal rod for noise.

In case of irregular or rough sound, the corresponding bearing must
be replaced.
Service & Maintenance
MAINTENANCE:
MOTOR
Motor bearings

Small and medium sized motors are equipped with closed bearing
running for several years without need of lubrication.

Bearings of larger motors, depending on the motor manufacturer and
motor size, are equipped with nipples for lubrication.

After three re-lubrications the bearings must be dismounted, cleaned
and greased again. For lubrication intervals under normal operating
conditions and 24 h/day load.
Service & Maintenance
RECOMMENDED SPARE PARTS FOR STORAGE
Section code
Description
Recommended Qty.
FH
Pre-Filter
2 sets for each unit for a year
operation
FTH
Bag Filter
1 set for each unit for a year
operation
V
Motor
1 no. for each motor size
For full details of recommended spare part list for each models and with their respective spare
part no. Please refer to the operation manual submittal.
Module 4
Troubleshooting
FAULT FINDING & TROUBLESHOOTING GUIDELINES
Troubleshooting
Symptoms
Problem Cause
Blown fuse or open circuit breaker
Replace fuse or reset circuit breaker
Overload trip
Check and reset overload
Improper wiring or connection
Check wirings
Improper current supply
Adjust actual supply power with motor
nameplate recommendation
Mechanical failure
Check the motor and drive rotate freely
Open phase
Check line for an open phase
Overload motor
Reduce Load
Low line voltage
Check across AC line
Motor Fails to Start
Motor Stalls
Recommended Action
FAULT FINDING & TROUBLESHOOTING GUIDELINES
Troubleshooting
Symptoms
Excessive Vibration
Motor runs and then
dies down
Motor does not come up
to speed
Motor Overheat
Excessive Motor Noise
Problem Cause
Recommended Action
Poor alignment
Aligned bearing set screws
Over tensioned belts
Adjust belt tension
Misaligned drive
Aligned drive
Partial loss of line voltage
Check for loose connection
Stater shorts when motor warms up
Replace starter
Low voltage at motor terminals
Check across AC line and correct
voltage loss
Line wiring to motor too small
Replace with larger sized wiring
Overload motor
Reduced load
Motor fan is clogged with dirt
preventing proper ventilation
Remove fan cover, clean fan and
replace cover
Motor mounting bolts loose
Tighten motor mounting bolts
Rigid coupling connection
Replaced with flexible connection
Wom motor bearings
Replaced bearing and seas
Fan rubbing on fan cover
Remove interface in motor fan
housing
FAULT FINDING & TROUBLESHOOTING GUIDELINES
Troubleshooting
Symptoms
Problem Cause
Incorrect airflow
Lower water coil capacity
Drain pan is overflowing
Incorrect water flow
Coil piped is incorrectly
Dirty fin surface
Plugged drain pan line
Unit not level
P-trap not properly sized
Standing water in drain
pan
Excess dirt in unit
Unit not level
Plugged drain pan line
P-trap not properly sized
Missing Filters
Filter by-pass
Recommended Action
Check fan operating condition
Inspect water pumps and
valves for proper operation
Verify coil piping
Clean the surface
Clean drain line
Level the unit
Verify P-trap height and install
correct design
Level the unit
Clean drain line
Verify P-trap height and install
correct design
Replace filters
Reduce filter bypass
OPERATION AND
INSTALLATION MANUAL
Module 5
\Manufacturer’s Contact details
(Technical and After Sales Service support
SERVICE / MAINTENANCE
CONTACT NUMBER
Contact Nos.:
Tel. No.:
Fax No.:
+974 4001 8888
+974 4001 8877
Contact Persons:
Mr. Saad Ishtiaq
Asst. Sales Manager
Email: Saad.Ishtiaq@euroclima.com
Mobile: +974 3000 2288
For Commissioning and Maintenance:
Ms. Mila Tomada
Sr. Application Engineer
Email: Mila.Tomada@euroclima.com
Tel.No.: +974 4001 8925 (direct)
Mr. Manivannan Moorthi
After-Sales Service Supervisor
Email: Manivannan.Moorthy@euroclima.com
Tel.No.: +974 7707 3734 (direct)
QUESTION & ANSWER