HVAC SYSTEM

OVERVIEW

TI Information – Selective Disclosure

This is a training document. It is necessary to
source definite parameter values from
specifications and through your trainer. The
values given in this document are for training
purposes only.
This package is part of the minimum training
curriculum for Mechanical/ HVAC personnel.
Additional training may be necessary to meet site-
specific requirements.
Objective

At the conclusion of this training, you will be able to:

· Explain the hazards associated with Air Handlers

•· List the equipment components
•· Explain Sequence of Operations
•· List targets and limits
•· Perform equipment troubleshooting
Scope of Package
• Safety Overview
• Introduction to HVAC
•Water Chiller and Refrigeration System
•Cooling Tower
• AHU
•Filters
•Fan
•Coil
•Ductworks
• MDS
• Air Properties and Psychrometry
•Humidity Control
Equipment-Specific
Safety Overview
Equipment-Specific Safety Overview

Objective

• Identify all equipment-specific electrical, chemical,

mechanical, pneumatic and waste-related hazards
associated with General Air Handlers.

• Explain the proper precautions to take while working on

or around the equipment.

.
Equipment-Specific Safety Overview

Safety Hazards
Identify and explain all ELECTRICAL hazards and precautions with
Air Handlers.

• 460/ 120 vac power •(PPE, LOTO, EEW)

Identify and explain all CHEMICAL hazards and precautions with Air
Handlers.

• oil, refrigerant, •(gloves, mask, goggles,

declogger, grease PPE)

Identify and explain all PNEUMATIC hazards and precautions with

Air Handlers.

• Fan Suction •LOTO

Equipment-Specific Safety Overview

Safety Hazards (cont.)

Identify and explain all MECHANICAL hazards and precautions with
Air Handlers.

• Moving Parts: •(Pulley Guard, LOTO)

Shafts, Pulleys,
Fans, V-belts

Identify and explain all WASTE-RELATED hazards and precautions

with Air Handlers.
• oil, grease •Haz waste disposal

Identify and explain all THERMAL hazards and precautions with Air
Handlers.

• Hot Surfaces: •(Gloves, PPE, General

Motors, Bearings Caution Signage)

AIR HANDLER LEVEL 2

HVAC

AIR HANDLER LEVEL 2

Brain Stimulation

 How many wolves can you

see?

Answer: Five wolves

Key Learning
 It only showed that we
do have different
interpretation in one
thing
H - Heating
V - Ventilation
A - Air
C - Conditioning
HVAC
refers to the
Indoor Comfort
Industry
Air conditioning includes
both the cooling and
cooling
heating of air.
heating
It also cleans and controls
cleans
the movement
controls and the
the movement
moisturemoisture
level of the air .
level
.

AIR HANDLER LEVEL 2

Typical Chilled Water Air Conditioning System

AIR HANDLER WATER CHILLER COOLING TOWER

Typical Chilled Water Air Conditioning System

COOLING TOWER

CHILLED PUMP

AIR HANDLING UNITS

CHILLER

CONDENSER PUMP
Typical Chilled Water Air Conditioning System

CONDENSER PUMP

COOLING
TOWER

CONDENSER WATER
LOOP
EVAPORATOR PUMP

CHILLER

CHILLED WATER LOOP

MAKE UP AIR AIR AIR AIR

HANDLER HANDLER HANDLER HANDLER HANDLER
UNIT UNIT UNIT UNIT UNIT
Typical HVAC Layout:

.
 Typical RH – MAH System
Return Air Fan

RAH

MAH

Factory

Chilled Water
A TYPICAL WATER CHILLER

Chiller - A device that produces chilled water (~40-50F) to

provide air conditioning (AHU) for large buildings and/or
cooling for process applications (PCW).
.
 Chiller Flow

EXPANSION
VALVE

CW OUT CHW OUT

HEAT FROM
REFRIGERANT HEAT FROM
TO CW CHW TO
REFRIGERANT

CW IN CHW IN

CONDENSER COMPRESSOR EVAPORATOR

REFRIGERATION SYSTEM COMPONENTS:

Condenser - This is the coil where heat is dissipated from the

refrigerant, changing the refrigerant from vapor to liquid.

Compressor - The heart of an air conditioning system which

draws a low pressure on the cooling side of the refrigerant cycle
and squeezes or compresses the gas into the high pressure or
condensing side of the cycle.

Expansion Valve - This is where the refrigerant is allowed to

expand from high to low pressure and cool the refrigerant to the
point where it returns to a liquid state.

Evaporator - This is the coil where the cold refrigerant liquid

absorbs heat from the space and changes state from a liquid to a
vapor (usually between 40 -50 F).
 Basic Refrigeration Cycle
Stage 3: The vapor refrigerant moves into the COMPRESSOR,
which raises its pressure and temperature (~120 -140 F)
Stage 4: The
increase in Stage 2: The refrigerant
pressure absorbs heat and
causes the changes from liquid to
refrigerant vapor (~ 40 -50 F)
to flow into
the outdoor
coil known
as the
CONDENSER
and release Stage 1: Cool, liquid
heat to the refrigerant enters the
outside air indoor coil known as
by a fan the EVAPORATOR
.

Stage 5: The vapor refrigerant then reaches the EXPANSION VALVE,

which causes it to "flash" through the valve, which reduces the pressure
and cools the refrigerant to the point where it returns to liquid state.
 EXPANSION
VALVE

Heat in

CONDENSER EVAPORATOR
COMPRESSOR

Diagram of a typical air conditioner

.
Cooling Tower – A heat rejection equipment to take away
the heat from the refrigerant in the chiller condenser and
rejects it to the atmosphere by heat of evaporation.

AIR HANDLER LEVEL 2

Cutaway View of a Cooling Tower
FAN
MOTOR
HOUSING
PANEL
SPRINKLER
PIPES

PVC
FILLER

HOUSING WATER
PANEL BASIN

OUTLET PIPE
INLET PIPE
Principle of Operation of a Cooling Tower:

1. A cooling tower blows air through a stream of water so

that some of the water evaporates.

2. Generally the water trickles through a thick sheet of an

open plastic mesh.

3. Air blows through the mesh at right angles to the water

flow.

4. The evaporation cools the stream of water.

5. Because some of the water is lost to evaporation, the

cooling tower constantly adds water to the system to make
up the difference.
Brain Stimulation
 How many faces
can you see?

Answer: Three faces

Key Learning
 It only showed that we
do have different
interpretation in one
thing
Air Handler
AHU (Air Handler Unit) - The inside part of the A/C system
that contains the blower, cooling (evaporator) coil, and
heater that is responsible for moving, cleaning, heating,
and/or cooling the air.
 General Classification of Air Handlers:

• Direct Expansion
The cooling effect is obtained directly from a fluid called a
refrigerant that absorbs heat at a low temperature and
pressure, and transfers heat at a higher temperature and
higher pressure.

• Chilled Water
The cooling effect is obtained indirectly from a separate
refrigeration system through the use of chilled water as a
secondary medium.

. .
Air Handler Components

Air Handling Systems May Have The Following Components Depending On Use

General Steam Chilled Water Air Pressure

Air Filters Coil Coil Humidifier Dampers
Hot Water High Efficiency
Return Fan Coil Dehumidifier Supply Fan Air Filters
Air Duct

Outside
Air
Grille

Mixed-Air Return Air Supply Air

Dampers Duct Ducts

Return Air HEPA/ULPA Supply Air

.
Grille Air Filters Grille
CUTAWAY VIEW OF A CHILLED WATER AIR HANDLER
A TYPICAL DRAWTHROUGH AIR HANDLER

MIXING BOX
FILTER
COOLING COIL
HEATING COIL
FAN
Filters
FILTER is the mechanism for removing undesirable
elements from entering the controlled space via the
air stream
Hygienic and Filtration
One of the major functions of an
air handling system is the cleaning
of the air through filtration.

AIR HANDLER LEVEL 2

Filters and Contaminants
PRE-FILTERS

The most common types of pre-filters are as

follows:
•Mesh type (aluminum or stainless
steel)
•Mesh type (electrostatic)
•Disposable
PRE-FILTERS

Mesh type (aluminum or stainless

steel)
•ASHRAE ratings ~ 5% - 15%.
•For high moisture or grease-laden air
•Washable
•Disadvantage - low efficiency, shorter final
filters life
PRE-FILTERS

Mesh type (electrostatic)

•ASHRAE ratings ~ 15-20%. (30% under lab
conditions)
•Higher efficiency than the metal mesh types
•Washable
•Disadvantages - cost and lower efficiencies,
shorten the final filters life
PRE-FILTERS

Disposable:
•ASHRAE efficiencies of 20% to 30%
• Most common filters used by ACU
manufacturers, commercial and
industrial
•Typically constructed from pleated, non-
fiberglass media
•Available in many sizes and typically in 2 or 4
depth.
FINAL FILTERS

The most common types of final filters are as

follows:
•ASHRAE Type
•DOP (Drop Oil Particulate) Type
FINAL FILTERS

ASHRAE Type
•Rated up to 95% efficient on a 1.0-micron
particle.
•Typically, 45% to 65% efficient filters are
used as an intermediate filter to
HEPA filters
•90% -95% filters are used as the final level
of filtration.
FINAL FILTERS

DOP (Drop Oil Particulate)

Type
• To meet HEPA minimum requirements,
99.97% of the particles need to be
removed.
•There are many kinds of DOP filters, ranging
from 95% DOP to 99.9997% HEPA filters.
•For most applications requiring this level of
filtration, such as microprocessor fabs,
99.97% efficiency is adequate.
 HEPA
stands for:
High
Efficiency
Particulate
Air filter
HEPA filters
were developed as a part
of the
Manhattan Project!
-used to remove radioactive
contaminants from the air in
the development of the
atomic bomb!
HEPA FILTERS

HEPA filters are usually used in two types of

situations:

•HEALTHCARE INDUSTRY
- to have a sterile environment

•CLEAN ROOM
- to remove as much particulate
from the air as possible
HEPA FILTERS

•CLEAN ROOM
examples of the type of electrical/electronic
component manufacturing where a single
spec of dust can ruin the entire circuit board:

•Computer Chips
•Computer Hard Drives
•Motherboards
•Cellular Phone Components
HEPA FILTERS

HEPA filters are manufactured in

different efficiencies from 95.0% to
99.997%, depending on the need

ULPA filter- a HEPA filter which will

remove 99.997% of particles the size
of 0.12 microns from the air.

AIR HANDLER LEVEL 2

PLEATED CARTRIDGE FILTERS
BAG FILTERS

AIR HANDLER LEVEL 2

HEPA FILTERS

AIR HANDLER LEVEL 2

Troubleshooting
Filters
Top Reasons HVAC Systems Get Dirty
1. No filters.
2. Gapped filters or poorly-fitted filters.
3. Poor filters.
4. Filters not changed or cleaned frequently.
5. Neglect of the units: not inspecting them occasionally to spot dirty
build-up or problems (such as filters not in place).
6. Dirty environment such as factory, new construction, or highway
nearby.
7. Duct leakage.
8. Poor or no condensation drainage.
9. Deteriorated fiberglass insulation.
10. Leaks in air-handlers, such as worn seals around doors or holes in
cabinets
NO FILTERS

By far the number-one way to contaminate a duct

system is to simply omit filters. This isn't a common
occurrence, but it does happen. Dirt stacks up
rapidly in the air handler and ductwork and is soon
pouring into the building.
GAPPED OR POOR-FITTED FILTERS:

This can happen in many ways, such as:

1. Missing filters.
2. Tears in the filters.
3. Wrong-sized filters.
4. Filters warped or bent by air suction.
5. Worn gaskets in the filter frame.
POOR FILTERS

ASHRAE has established some basic

recommendations for filters. One of the ways filters
are rated is the "dust-spot" method. This measures
how efficiently a filter captures particles in the 0.3-
6-micron range. The rate of efficiency is measured
in percentages, such as a "30-percent dust-spot
efficiency."
FILTERS NOT CHANGED OR CLEANED FREQUENTLY

The filter becomes more of a barrier to the air flow.

The blower motors strain.
The HVAC system puts out less air.
Clogged filters are more likely to tear from the air
pressure or warp or get sucked into the air handler.
Dirty filters act as a breeding ground for microbes
which can then get into the air stream.
NEGLECT OF THE UNITS

Neglect to inspect the inside of the air handlers

can lead to clogged filters, torn fiberglass
insulation, standing water, frayed fan belts, and
maybe a few bird nests.
A simple inspection of the unit every time the filters
are changed could improve air quality, reduce the
need for cleaning, and extend the life of the air
handler.
e Procedures

Air Filters
•To replace throwaway filters, install new filters with the
directional arrows pointing in the direction of airflow.
•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 with protective oil film and allow to
drain and dry for 12 hours
Centrifugal Fan
A FAN is simply the device that creates the pressure differential
to move air through the system.
BLOWER ASSEMBLY

Backward Inclined
 Proper rotation for the most common wheels

•A common problem is wheel rotation in the wrong

direction.
• For centrifugal fans, incorrect wheel rotation will still provide
some airflow.
• With a 3 phase motor, changing any two supply power
connections will reverse the direction of rotation.
.
DETERMINING STATIC PRESSURE

The pressures generated by fans in ductwork are very small. Yet,

accurately estimating the static pressure is critical to proper fan selection.
Fan static pressure is measured in inches of water gauge.
1 psi = 27.7" of water gauge
Static pressures in fan systems are typically less than 2" of water
gauge, or 0.072 psi

.
UNIT START UP

1. Disconnect and lock-out all power switches to fan.

2. Check all fasteners, set screws and locking collars on the fan,
bearings, drive, motor base and accessories for tightness.
3. Rotate the fan wheel by hand and assure no parts are rubbing.
4. Check for bearing alignment and lubrication.
5. Check the V-belt drive for proper alignment and tension.
6. Check the all guarding (if supplied) for being securely attached and not
interfering with rotating parts.
7. Check operation of variable inlet vanes or discharge dampers (if
supplied) for freedom of movement.
8. Check all electrical connections for proper attachment.
9. Check housing and ductwork, if accessible, for obstructions and
foreign material that may damage the fan wheel.
CAUTION!

• When installing a fan, ensure the proper protective

devices are used to protect personnel from moving parts
and other hazards. Protective accessories include: inlet
guards, outlet guards, belt guards, shaft guards,
protective cages and electrical disconnects.
• Check local codes to ensure compliance for all
protective devices.
• For further details on safety practices involving industrial
and commercial fans please refer to AMCA Publication
410.
CAUTION!

ELECTRICAL DISCONNECTS
All fan motors should have disconnects located in
close visual proximity to turn off electrical service.
Service disconnects shall be locked out when
maintenance is being performed.
CAUTION!

MOVING PARTS
All moving parts must have guards to protect personnel. Refer
to local codes for requirements as to the number, type and
design. Fully secure fan wheel before performing any
maintenance.
The fan wheel may start “free wheeling” even if all electrical
power has been disconnected. Before the initial start-up or any
restart, check the following items to make sure that they are
installed and secure.
CAUTION!
MOVING PARTS
ACCESS DOORS
Before opening access doors ensure the fan wheel has
stopped moving and that the wheel has been secured
from being able to rotate. Do not operate fan without
access door in its fully closed position.
GUARDS ( BELT, SHAFT, INLET, OUTLET)
Do not operate fans without proper protective devices in
place. Failure to do so may result in serious bodily injury
and property damage.
CAUTION!

AIR PRESSURE AND SUCTION

In addition to the usual hazards associated with rotating
machinery, fans also create a dangerous suction at the inlet.
Special caution needs to be used when moving around a fan
whether it is in operation or not.
Before start-up, make sure the inlet area is clear of personnel
and loose objects.
Troubleshooting
and
Maintenance
Fans
Analysis
Symptom Probable Cause Recommended Action
Bearing is First start after lubrication. Allow machine to cool down and restart
excessively (grease distribution)
hot
Over tensioned belts Tension belts
No lubricant Apply lubricant. Check bearings for damage
Misaligned bearing Correct alignment. Check shaft level
Motor fails to Blown fuse or open circuit Check and replace fuse and reset circuit
start breaker breaker
Overload trip Check and reset overload

Improper wiring or Check wiring with diagram supplied on unit

connections
Improper current supplies
Mechanical failure
Compare actual with motor nameplate
recommendations. Contact power company
for adjustments
Check that motor and drive rotate freely.
Check bearing lubricant

Motor does Low voltage at line terminals Check across AC line and correct voltage
not come up loss if possible
to speed
Line wiring to motor too small Replace with larger sized wiring
 Symptom Probable Cause Recommended Action

Motor stalls Open phase Check line for an open phase

Overloaded motor Reduce load or replace with bigger motor
Low line voltage Check across AC line. Correct voltage if
possible

Shipping spacers not Remove shipping spacers and/or bolts

removed
Over tensioned belts Tension belts
Misaligned drive Align drive
Motor runs Partial loss of line voltage Check for loose connections. Determine
and then dies adequacy of main power supply
down
Stator shorts when motor Replace stator
warms up
Excessive Motor mounting bolts loose Tighten motor mounting bolts
motor noise
Rigid coupling connections Replace with flexible coupling connections
Worn motor bearings Replace bearings and seals
Motor fan rubbing on fan Remove interference on motor fan cover
cover
 Symptom Probable Cause Recommended Action
Motor Overloaded motor Reduce load or replace with bigger motor
overheats
Motor fan is clogged with dirt Remove fan cover, clean fan and replace
preventing proper ventilation cover
Rapid motor Excessive overhung load due Check belt tension and overhung load
bearing wear to over tensioned drive

Excessive overhung load due Replace sheave with larger one

to small diameter motor
sheave

Bearing noise Poor alignment Loosen bearing setscrews and realign

Inadequate lubrication Grease bearing(s)
Short belt life Worn sheaves Replace sheaves
Misaligned belt Realign drive at mean pitch diameter
Grease or oil on belts Check for leaky bearings. Clean belt and
sheaves
Belt slipping Adjust tension
Belts rubbing Remove obstruction or realign drive for
clearance
sis

Symptom Probable Cause Recommended Action

Loose fan Motor is poorly positioned Adjust tension

belt
Worn or damaged belt Replace belt or belt set. Check sheave
alignment

Worn sheaves Replace sheaves

Low coil Air is bypassing coil
capacity
(Chilled Coil tubes are blocked
Water) Incorrect airflow
Incorrect water flowrate
Incorrect water temperature
Low coil Air is bypassing coil
capacity
Coil tubes are blocked
(Refrigerant)
Incorrect airflow
Expansion valve not operating
Poor refrigerant distribution
Prevent bypass with block-off
Clean and unblock tubes
Check fan operating condition
Check water pumps, valves and lines for
obstructions
Provide proper water temperature
Prevent bypass with block-off
Clean and unblock tubes
Check fan operating condition
Check sensing bulb location and TXV
operation
Check for blockage in distributor and tubes
 nalysis

SYMPTOMS

Pulley wobble
Belt cover split

Belts bottoming

Bearings are hot

Belt soft, swollen

Belts ride too high

Cracked bushings
Shaft whip or bend
Underside cracked
Tie-band damaged
Repeated breakage
Worn cover on back
Rapid side wall wear
LEGEND
Most Common Causes

Repeated take up necessary

Belt slips, squeals (spin burn)
Belt turns over or jump off pulley
With Other Possible Causes
Pulley and Belt

X
O

Belts vibrate excessively or appear mismatched

CAUSES

o
o
o

Belt pries on or misplaced slack

x

Belt rubbing guard

Pulley misalign

x
o o x
x
o o x

o
o
o o
o
o
Worn or damage pulleys
Pulleys too far from bearing

o
o o o
o o o
Poor bearing or shaft condition
x

o
o
o
o

Insufficient tension

x
x
o o Excessive tension

x
x
Improper pulley installation
Belt worn (normal service)
x

o
o o
o
o
o

Wrong belt cross-section or type

Mismatched or mixed belts
o x
x

Machine induced impulse or shock

Improper or prolonged storage
o x

Excessive heat
o

Excessive oil or grease

o
x o

Use of belt dressing

o o o o o

Abrasive environment
x
o
o
o

Foreign objects in grooves

o

Excessive moisture
x
x
o o

Overloaded drive- underbelting

o

Drive seriously overbelted

x

o o
o o

Pulley too small

o

Insufficient wrap on small pulley

o
o

Backside idler
ce Procedures

Fan Bearing Lubrication

•Fan bearings that are permanently sealed and
lubricated must not be relubricated

Fan Motors
•Inspect periodically for excessive vibration or
temperature.

AIR HANDLERLEVEL 2
nce Procedures

Motor Bearing Lubrication

•Most small frame motors comes without oil tubes or grease
nipple where the bearings are permanently sealed
•The motors with double shielded bearings are lubricated for
life and cannot be relubricated
•For bigger motors that have open bearings, “flush through” re-
greasing facilities are provided.
ce Procedures

Motor Bearing Lubrication

• To re-lubricate, complete the following:
1. Turn the motor off and provide LOTO
2. Remove the relief plug and clean out any hardened
grease
3. Add fresh grease through the fitting with low pressure
grease gun
4. Run the motor for few minutes to expel any excess
grease through the relief vent
5. Stop the motor and replace the relief plug
ce Procedures

Motor Greasing Intervals

Rated Poles Relubrication Period
Output, Standard Sever
KW Condition Condition
0-30 4 upwards 7 years 3 years

37-75 4 upwards 210 days 70 days

90-110 4 upwards 90 days 30 days

Standard Condition: 8 hr/day operation with rated or light loading in clean and low
vibration environment
Severe Condition: 24 hr/day operation with rated or light loading or in a dirty /dusty
environment or where the motor is subject to vibration/light shock loading

AIR HANDLER LEVEL 2

Troubleshooting
Condensate Trap
Problem: NO TRAP ON SYSTEM

Results: No seal, air inflow, improper drainage

Consequences: •Water carry-over to ductwork
•Admission of potentially contaminated air
•Bacterial growth
•Potential water back-up and unit damage
Problem: TRAP OUTLET IS TOO SHORT

Results: Seal destroyed at start-up, air inflow, improper drainage

Consequences: •Water carry-over to ductwork
•Admission of potentially contaminated air
•Bacterial growth
•Potential water back-up and unit damage
Problem: TRAP OUTLET IS TOO TALL

Results: Improper drainage

Consequences: •Water back-up and unit damage
•Bacterial growth
Problem: DRAIN PANS “GANGED" TOGETHER
ON SINGLE TRAP

Results: Air inflow through drain line, seal bypassed, improper drainage
Consequences: •Water carry-over to ductwork
•Admission of potentially contaminated air
•Bacterial growth
•Potential water back-up and unit damage
Problem: “AIR LOCK" IN DRAIN LINE

Results: Improper drainage

Consequences: •Water back-up and unit damage
•Bacterial growth
PROPER TRAPPING

Positive Pressure Trap

RAPPING

Negative Pressure Trap

NANCE CONCERNS

Clean-out left open

intenance Procedures

Coil Cleaning

•Steam, hot water and chilled water coils should be kept clean to
maintain maximum performance.
•If fins become dirty, clean with steam and detergent, hot water
spray and detergent, or one of the commercially available
chemical coil cleaners
• Rinse coil thoroughly after cleaning
ce Procedures

Coil Cleaning
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.
•Read the MSDS and secure the needed CUA.
ce Procedures

Coil Cleaning
•For DX units, refrigerant coils must be kept clean to
maintain maximum performance
•If fins become dirty, clean with cold water and detergent
or one of the commercially available chemical coil
cleaners.
•Rinse coils thoroughly after cleaning
nce Procedures

Refrigerant Coil Cleaning

WARNING:
•Never use steam or hot water to clean a refrigerant coil.
Dangerous pressures may be built up by improper
application of heat resulting in equipment damage and/or
personal injury
nce Procedures

Coil Winterization

• Provisions must be made to drain the coils that are not

in use when subjected to freezing temperatures
• To drain these coils:
1. blow out the coils with compressed air,
2. fill and drain the tubes with full-strength ethylene glycol
several times,
3. and then drain the coils as completely as possible.
ce Procedures

Coil Winterization

CAUTION:
Failure to properly drain and vent coils when not in
use during freezing temperatures may result in coil
freeze-up damage.
Ductwork
AJOR COMPONENTS OF A DUCTWORK

Duct - A pipe or closed conduit made of sheet metal, fiberglass board,

or other suitable material used for conducting air to and from an air
handling unit at relatively low pressures. Ductwork is one of the most
important components of space heating and cooling system.

Damper - A device that is located in ductwork to adjust air flow.

There are basically two types of dampers:
•Manual - generally consists of a sheet metal flap, shaped to fit the
inside of a round or rectangular duct and manually rotated
through a handle located outside to adjust air flow to match the
needs of a particular area or room.
•Motorized - generally used in a zoned system to automatically deliver
conditioned air to specific rooms or zones.
MAJOR COMPONENTS OF A DUCTWORK (cont.)

Plenum - The portions of the air distribution system that makes use of the
building structure. Also the sheet metal that connects distribution
ductwork to an air handling unit. Many buildings use the space above a
dropped ceiling as a plenum.

Registers - Combination grille and damper assembly covering an air

opening or end of an air duct. Coverings for the ducts where they open
to the conditioned space.
MEASURING AIR PRESSURE

ATMOSPHERIC
ATMOSPHERIC
PRESSURE
DUCT TO DUCT PRESSURE
PRESSURE

20

10

0 30 mm
10

20
U TUBE
MAGNEHELIC
DIGITAL MANOMETER
Troubleshooting

Ductwork

AIR HANDLER LEVEL 2

 OSA = Exhaust + SP

Interstitial Make-up Warm

Air Handler Outside
Supply Duct Air

Air Handler
Fan
Return
Warm
EF Duct
Exhaust
Air

Mfg Room

Exfiltrated Air
due to Space
Pressurization

Tool

Basic A/T HVAC System

 Interstitial
Positive Pressure
Supply Duct Return Duct
Cold Air Sealed
Leaking Air Handler
Out Fan

Mfg Room
Negative Pressure
Warm Air Leaking
into Mfg Room

Duct System
With Supply Duct
Leakage
 Interstitial
Negative Pressure
Supply Duct Return Duct
Sealed Warm Air
Air Handler Leaking in
Fan

Mfg Room
Positive Pressure
Cold Air Leaks to
the Outside

Duct System
With Return Duct
Leakage
 Interstitial
Neutral Pressure
Supply Duct Return Duct
Cold Air Warm Air
Leaking Air Handler Leaking in
Out Fan

Mfg Room
Neutral Pressure

With Leakage in Both

Supply and Return
Ducts

AIR HANDLER LEVEL 2

 Interstitial
Neutral Pressure
Supply Duct Return Duct

Air Handler
Supply Duct at Fan Return Duct at Low
High (+) Pressure (-) Pressure

Mfg Room

Cold Air Leaks to Warm Air Leaks

the Outside from the Outside
Mild High (+) Mild Low (-)
Pressure Pressure

Excess Air Leakage

Caused by Isolation of
Zones
Design Standard

Standard 1254-A
A/T Class 10,000 And 100,000
Makeup And Recirculating Air
Conditioning Systems (HVAC)

Standard 1251-A
A/T General Air-Handling Systems
.
General Functions of Air Handlers:

• General Air Handler

• Recirculating Air Handler

• Make-up Air Handler

.
General Air Handler (AH)

•Provides fresh outside air mixed with return air.

•Serves areas that do not need precise temperature

and/or humidity control.
•These areas include:
• offices
• mechanical rooms
• laboratory areas
• computer rooms

•Air distribution is through series of air ducts. Each

zone has temperature sensor and damper
system to control temperature.
.
HU Arrangement

Air Outside Pre AHU Inlet AHU

AHU Coil AHU Fan
Handler Air Grille Filtration Filters Discharge

• Constant • Rain- • 2”-4” • 4” Thick • Direct • Forward

–Volume • Up out of
Proof Thick - 30% Expansion Curve
Draw - top of Unit
Louver Disposable ASHRAE Multi- Multi-Belt
Through on in OSA Mounted Circuit, with Driven • Automatic
Coil and Building Inlet Duct on Filter Serpentine Centrifugal Backdraft
Filter Exterior Frame Coils Fan and Manual
• Odor-
• Water- that Opposed-
Absorbing •Multi Row
Cooled DX comes Blade
Carbon Coil up to
or Chilled with Unit Dampers on
Filters 28 F delta
Water Coil Outlet
(Non- POR) • Flow < (dry)
• 4” Filter 500 fpm
• Flow < 500
Rack fpm
eneral Air Conditioning Environmental Matrix

Operational
Parameter Set Point Sensor Location
Tolerance
Center of zone
served by A/C, away
Temperature 73F +/- 5F
from diffuser. Hung
15” below ceiling

Humidity None <70 % RH NA

Outside Air 20 scfm/person see pressurization NA

Noise Level –
</= NC 45 +/- 5 NC NA
No Tools
0.05 cfm/sq ft or 20
>0.001” w.c.
Pressurization cfm/person, NA
positive to outdoors
whichever is greater
 GENERAL AIR-HANDLING SYSTEM

AH-1
TT1 TT2

AH-2

AH-3
TT3 TT4

AH-4

KEY
BACKDRAFT
LOCAL CONTROL DAMPER
OUTSIDE AIR PANEL
OPPOSED
BALDE DAMPER
TEMPERATURE TT1
TRANSMITTER
FILTER
Recirculating Air Handler (RAH)

• provides general air conditioning for open areas

(e.g. machine rooms)
• provides precision air conditioning to the
manufacturing area:
• sensible cooling to the area
• comfort to workers
• space cleanliness:
- Class 10K with < 10,000 particles
(at 0.5 m or larger) /ft3 of air

- Class 100K with <100,000 particles

(at 0.5 m or larger) /ft3 of air

AIR HANDLER LEVEL 2

Major Elements of a Cleanroom RAH
Element Design Criteria
Chilled Water coil units.
Unit configuration Class 100K: Single Wall Construction
Class 10K: Double Wall Construction (to cover insulation)

Location Inside building in air handling rooms.

In countries where Smoke Exhaust is not required, the AHU rooms

are the return air plenum; return air from mfg area comes back
through ceiling return grills and sheet-metal return ductwork into
room. Return duct terminates at AHU room floor to structure wall.
The openings into the air handler rooms are protected with fusible
link fire dampers.
(Malaysia & China requirement: For sites with smoke exhaust
Return air plenum requirements, return air ductwork also serves as smoke exhaust
(Smoke Exhaust – duct. The return duct does NOT terminate at entrance into AHU
Malaysia & China) rooms, instead it is ducted all the way back to each individual RAH.
Smoke Exhaust Fans and isolation dampers are connected to some
of these return air ducts and the smoke is discharged to outdoors.
Thicker gauge return duct and all metal noncombustible
components (no flex duct or non metal grills) are used. Smoke
exhaust fans draw return air from zone and discharge it to outside
upon activation of Smoke Removal System. Interlocks and
dampers shut down & isolate RAH’s.)
Major Elements of a Cleanroom RAH
(cont.)
Element Design Criteria

N+1Redundancy: With all units operating, each will supply ~27,000 cfm. In case of
Min of 4N/4 AHU’s. failure of one unit, others can be manually ramped to 30,000 cfm by
Compressors opening O.B.D. on discharge.

Return air grills and supply diffusers will need some

accommodation to layout. The air balance is initially uniform, but
after tools are installed each supply diffuser can be adjusted to
Layout dependency
compensate for hot or cold spots. However as subsequent tools
are added or removed, the heat load from the tools will require
adjustment of diffuser airflow.
PLC’s not required for packaged AHU’s when they have a Local
Control Panels (LCP) with internal temperature controllers and
temp thermistors located in center of the zone it serves. Standard
configuration is thermistors supplied with units mounted in mfg
PLC / controls area zone. PLC’s are used for monitoring and alarming.
configuration POR configuration is temperature transmitters located in center of
zone inputting into BMS, software in BMS controls cooling
required by AHU. In both POR and Non POR configurations ALL
the temperature thermistors are averaged together for Functional
Area Environmental Spec conformance trending and reporting.
Major Elements of a Cleanroom RAH
(cont.)
Element Design Criteria

Class 100K : 30% ASHRAE 52.1-92 rated

Inlet Filter Class 10K : 95% ASHRAE 52.1-92 rated
Both : Maximum Velocity < 500 feet/minute
Multi-row, direct expansion; sensible cooling only; capacity given
Sensible cooling in IMS
coil
Maximum velocity <500 feet/minute

Belt drive centrifugal fan with fixed sheaves; maximum capacity of

Fan 30,000 cfm with 1.25” w.c. maximum external static pressure (ESP).
3.4” w.c. TSP (includes filter static loss)

VSD No

Humidifier Not required

Final Filter Not required

Dampers Discharge opposed blade and backdraft dampers

Recirculation air handlers discharge into common supply duct
Discharge Duct plenum installed above the units. RAH supply air mains are
Configuration installed above the ceiling and secondary steel. Ceiling diffusers
are connected to supply air duct via insulated flex duct
Design Basis for Cleanroom Airflow Rate and Capacity:
Parameter Criteria
Class 10K: 40/hr with 95% filters in recirculation air handlers (RAH’s).
Class 100K: Air change rate based upon heat load with 30% filters in
Air change rate RAH’s.
(All classes: 30%, 95% and HEPA filtered makeup air in makeup air
systems)
[Non-POR Air [Class 10K alternate: <40 per hour with ceiling HEPA filters, rate
Change Rate] based upon heat load requirements but not to be below 25.]

Nominal internal ~103 btuh / sq. ft. (30 watts/sq. ft.) this includes sensible heat from
sensible load tools, lights, people and roof heat transmission; ~89 btuh / sq. ft. (26
watts/sq. ft.) equipment only.
Manufacturing 11 +/- 1 ft
ceiling height
0.05 - 0.1 cfm/sq. ft. allowance for leakage dependent upon functional
area (see FTS for process).
Space Fresh air and ventilation (minimum 20 cfm per person in zone) must
pressurization be provided.
Usually the make up air exceeds 20 cfm of OSA/person because of the
process exhaust load (confirmation is required in all designs).
Room vibration Per Facility Target Spec white paper for process.
specification
om Environmental Matrix

Monitored
Parameter Set Point Operational Tolerance Sensor Location
By FMS?

Controlled Space -
Class 10K & Any set
center of zone, 16”
100K Areas- point 68 65 – 78 F Yes
below ceiling
Temperature - 73F
(Min. of 4 / area)

Class 10K & Next to temperature

100K Areas – 45 % RH +/- 5% RH Yes sensor. (Min. of 4 /
Humidity area)

<10K particles / ft3 air 0.5m

Class
FOL and Die <2.3K particles / ft3 air 1.0m
10,000 No N/A
Prep Areas <0.5K particles / ft3 air 2.0m
eq.
<70 particles / ft3 air 5.0m

<100K particles / ft3 air 0.5m

Class
EOL and Test <23K particles / ft3 air 1.0m <5K
100,000 No N/A
Areas particles / ft3 air 2.0m <0.7
eq.
particles / ft3 air 5.0m

Measured at
Noise level < NC 50 +/-5 NC No startup; no
discernible tones
nroom Environmental Matrix

Note:

• A/T whitepaper AT97009 modifies Cleanroom designation based upon

Particle counts using 95% filtration instead of HEPA filters.

• A/T whitepaper AT97028 modifies humidity requirement to 45%

plus/minus 5% and not to exceed 40% minimum/50% maximum.

• C4/BGA Environmental Conditions Matrix defines Temperature and

Humidity setpoints and ranges for all areas of A/T buildings.

• A/T whitepaper ATxxxxx modifies Cleanroom control from RH to Dew

Point of 50 +/- 3 F.
.
Make-up Air Handler (MAH)

• provides fresh outside air to an enclosed area.

• typically has no return air component, drawing

100% outside air.

• air may be further conditioned using additional air

handlers.

• A/T Class 10,000 and 100,000 makeup conditioning

system provides:
- clean makeup air
- humidity control
- space pressurization
.
Elements of a Cleanroom MAH

Element Design Criteria

Unit configuration Chilled Water based units.
Double Wall Construction
Outside air louver, & Louver< 500 feet / minute to exclude rain, or under covered awning.
inlet duct [Carbon odor absorbing filters (not POR) are optional at some sites,
[Carbon Filters] located in inlet ducting prior to makeup air handler. Protected upstream
and downstream with 20% efficient throw away filters.]

Outside Air Damper & Outside Air duct and damper is sized for 100% of MAH flow.
Recirculation Air Recirculation Air Bypass Damper & duct is sized for 80% of the total
Bypass Dampers MAH flow. Recirculation air is drawn from return air from cleanroom
back into inlet of makeup air handler. This allows MUA systems to
operate at constant flow. During startup of factories when no tool
exhaust/heat load is present it provides maximum dehumidification to
building. As tool exhaust is added and more pressurization is required
this Recirculation Air Bypass Damper closes as the OSA Damper opens
using pneumatic actuators. The BMS Building Pressurization Sensors
control these actuators/dampers to maintain a constant positive
pressure inside the cleanroom.
[Note: When Smoke Exhaust System is used, the building
pressurization system will automatically sense loss of cleanroom
pressure and modulate to 100% OSA in order to try and maintain
building pressurization. A&E engineer must determine if this is
acceptable to local code.]

.
AIR HANDLER LEVEL 2
Major Elements of a Cleanroom MAH (cont.)

Element Design Criteria

Prefilter 4” deep, 30% ASHRAE 52.1-92 rated, Maximum velocity <500 feet /
minute (Carbon odor filters optional at some sites, located in the inlet
duct prior to the makeup air handler. If these are installed, pre & post
filters are required).
Pre-dehumidification Multi-row direct expansion cooled, maximum velocity <500 feet / minute.
/ cooling coil (in Constant temperature/flow system intended to provide preconditioned
MAH) air into dehumidifiers. Duct mounted thermistor in discharge of each
makeup air handler is set at the maximum dry/wet bulb condition the
desiccant dehumidifier can accommodate to meet the dehumidification
load. Condensate drain pan to be sloped continuously to the drain
connection so there is never stagnant water in system.

Fan Belt drive centrifugal fan, can use adjustable sheaves if motor HP is
below 5. Maximum capacity of 18,000 cfm with adequate static pressure
to overcome component resistance + static of pre filter, carbon and post
filters on inlet (if used) and allow up to 1” w.c. drop for filter loading.

VSD No
Reheat Coil Not required
Final filters 95% ASHRAE 52.1-92 rated and 99.99% HEPA filters located on
discharge duct of dehumidifier. Maximum velocity <500 feet / minute.
Pressure to overcome flow resistance of filters is provided by the
desiccant dehumidifier process fan.
 Major Elements of a Cleanroom MAH (cont.)
Element Design Criteria
Dehumidifier/ Dehumidification is via cooling coil (Non POR - desiccant wheel /
Humidifier electric resistance heat regenerated type) capable of dehumidifying the
(Non POR, used in air to a dewpoint below the controlled space. Dehumidifier or coil
CR3 and previous) capacity is determined by the load from outside air and infiltration into
humidity-controlled areas from surrounding areas. Inlet design is 58
degF, saturated; leaving wheel design is 5.5 grains/lb air.
Non-POR Humidifier is pan type electric resistance heat, steam
generating type or air atomizing type. Humidifier adds moisture to the
makeup distribution duct main after the dehumidifier filters. The
dehumidifier & Humidifier never operate simultaneously.

Discharge ductwork Makeup air handler delivers air into dehumidifier. Dehumidifier fan
draws air through desiccant wheel and discharges air into duct with
95% and HEPA filters. After HEPA filter, air is ducted to inlet of each
Recirculation Air Handler with a volume control damper.

Return ductwork The makeup air system is intended to be a once through supply system
at full load. During partial load conditions the return duct and bypass
damper allow 80% of the makeup air to be recirculated. The amount of
outside air and return air is controlled by air actuated OBD dampers,
PLC and very low static pressure sensor that references manufacturing
area to the surrounding corridor.

Redundancy 2N/2 Minimum of 2 parallel Make Up Air Systems. Each system sized for 60%
of the design load (see schematic at end of SDS)

AIR HANDLER LEVEL 2

Major Elements of a Cleanroom MAH (cont.)
Element Design Criteria
Dehumidifier Bypass Manually adjustable damper that controls the ratio of air passing
Damper through dehumidifier to amount bypassing it. The balance of air
bypassing dehumidifier wheel is dependent upon the engineering
calculations and must be specified in the design.

Location In air handling rooms inside building. Can be exterior mounted with
proper weather protection and maintenance access.

PLC / controls Duct mounted thermistors (supplied by AHU mfg.) are mounted on
configuration discharge of MUA units to provide constant leaving air DB/WB
temperature (50/50 min, 58/58 max) to dehumidifiers. Humidity
transmitters for dehumidifiers are mounted in both the discharge
ductwork after the dehumidifier and in the manufacturing area being
controlled. BMS PLC provides 4-20 mA signal to modulate reactivation
heater stages, which in turn dry out the desiccant wheel, and
subsequently maintains specified relative humidity in the space. One of
the heater banks in dehumidifier is SCR controlled by a 4-20 mA input,
the rest are staged on and off to allow the BMS system to provide 0-
100% linear control of reactivation heat. The software required to
modulate the dehumidifier heaters must take into account the time delay
between increasing reactivation heat, and the subsequent drying out of
the zone it serves (usually between 2 and 5 minutes of delay). A double
PID loop configuration is used; the first loop modulates the reactivation
heaters to maintain desired discharge dehumidifier dewpoint, which in
turn is reset by the condition in the mfg space.

AIR HANDLER LEVEL 2

AIR
PROPERTIES
Dry Bulb Temperature (DB) - The temperature measured by a
standard thermometer. A measure of the sensible temperature of
air.

Wet Bulb Temperature (WB) - The temperature at which water,

by evaporating into air, can bring the air to saturation at the
same temperature.

Dewpoint (DP) - Is the temperature at which air becomes

saturated with water and begins to condense - forming a dew.
at 100 % RH : ambient temperature = dewpoint temperature.

Relative Humidity (RH) - The ratio of the water vapor pressure to

the saturation vapor pressure (over water) at the temperature of
the gas.
Enthalpy - The quantity of heat necessary to raise the temperature
of a substance from one point to a higher temperature. The quantity
of heat includes both latent and sensible.
Phase – the states of existence for a substance: solid, liquid or gas.

Absolute Humidity - This is often confused with mixing ratio. It is the

ratio of the mass of water vapor to the unit volume of moist air.

Latent Heat - Heat, that when added or removed, causes a change

in state - but no change in temperature.

Sensible Heat - Heat, that when added or removed, causes a change

in temperature but not in state.

Latent Cooling Load (or Latent Load) - The cooling load caused by
moisture in the air. The net amount of moisture added to the inside air
by plants, people, cooking, infiltration, and any other moisture source.

Sensible Cooling Load - The heat gain of the space due to

conduction, solar radiation, infiltration, appliances, people, and pets.
This sensible load raises the dry-bulb temperature.

AIR HANDLER LEVEL 2

Typical Sling Psychrometer

AIR HANDLER LEVEL 2

Humidity
Control

.
Humidity and Temperature

Humidity - is water vapor or moisture

content always present in the
air.

- is definable as an absolute
measure :

the amount of
water vapor in a
unit of air
AIR HANDLER LEVEL 2
Humidity and Temperature

Relative Humidity
is the ratio of the actual partial vapor pressure to
the saturated partial vapor pressure at the same
temperature.
This is, expressed by the formula:

AIR HANDLER LEVEL 2

Humidity and Temperature

Relative Humidity

- indicates how dry or

damp the air is

AIR HANDLER LEVEL 2

Humidity and Temperature

Relative Humidity
- the amount of water
vapor in the air
compared to the
amount the air can hold
at a given temperature
* definition is true at temperatures and pressures
normally encountered in building systems

AIR HANDLER LEVEL 2

Humidity and Temperature

“at a given temperature”

is the key to understanding relative humidity

Warm air can

hold more
moisture than
cold air
AIR HANDLER LEVEL 2
Humidity and Temperature

10,000 cubic feet of 70F air can

hold 80,550 grains of moisture

The same 10,000 cubic feet of

air at 10F can hold only 7,760
grains of moisture

70°F
80,550 Grains 10°F
7,760 Grains
Humidity Control
Humidity Control

PREREQUISITES FOR
MICROBIAL GROWTH
AIR HANDLER LEVEL 2
Humidity Control

two most common types of HVAC systems from the standpoint of

their ability to control space humidity:

• Constant Volume System

• Variable Air Volume System

dity Control

Constant-Volume (CV) Systems-

In the constant-volume, variable

temperature systems,
the amount of air supplied to a space is
held constant
while the temperature of the air delivered
is varied
to satisfy the thermal comfort
requirements of the space.

AIR HANDLER LEVEL 2

Two Common Methods to Address Part-load
Humidity Control Challenge in a CV System are:
• Use of an “Active Humidity Control Strategy”
Supply-Air Tempering
or
REHEAT

• Use of a dedicated, central air handler to separately

condition the outdoor air
MAKEUP AIR HANDLER
Basic Components of
ACTIVE HUMIDITY CONTROL STRATEGY
Dedicated Outdoor-Air System

.
 CV1 Air Handling Units

THANK
YOU!
Questions
 DOCUMENT REVISION HISTORY
Document Review
Revision No. Revision Date Nature of Revision
Participants
F 7/11/2015 Review and change training format Natz Salipan / Jerome B./ Jared

E 2/9/2014 Review and update Natz Salipan / Jerome B./ Jared

D 2/11/2013 Review and update Natz Salipan / Jerome B.
C 05.24.2012 Review and update Natz Salipan
B 7/9/2011 Review and update Natz Salipan
A 4/21/2010 Date of Original Document Natz Salipan

12/15/2019 “TI Proprietary Information - Strictly Private” or similar placed here if applicable 149
Quiz:

1. What is AHU? Draw a typical schematic diagram of AHU.

2. What is HVAC and ASHRAE?
3. What is chiller?
4. Enumerate the component of refrigerant system.
5. What is the job of a filter?
6. What is HEPA?
7. Give at least 3 properties of air?
8. Name at least measuring device for air pressure?
9. What is humidity?
10.What is LOTTO? Why is this important during PM schedules.