4201-230 DESIGN & CONSTRUCTION OF BOROUGE PERMANENT WAREHOUSES

KHIA7-2C, KIZAD ABU DHABI UAE

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Project Code: 4201-230

Project Name:
Borouge Permanent Warehouses

Training Module:
Operation and Maintenance Training of HVAC Equipment
(CCU UNITS)

Training Presented By: Eng. Mostafa Hassan & Mr. Victor

Section 01: Introduction
Section 02: Safety Instruction
Section 03: Warning
Section 04: Training Module
Section 05: System Description
Section 06: Operation Procedure
Section 07: Maintenance Procedure & Instruction
Section 08: Emergency Contact

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 Section 01
Introduction
The CCU system designed and installed to provide cooling and ventilation to the IT server room at
office building of the Borouge Permanent Warehouses.
This TRAINING MANUAL of the CCU System installed at the project (AD Port Project 4201-230)
DESIGN & CONSTRUCTION OF BOROUGE PERMANENT WAREHOUSES in KIZAD is for the
safe and reliable operation and maintenance.
The training covers;
 Operation of the CCU Units.

 Trouble Shooting and/or Proper Maintenance

The CCUs are manufacture by Cantal, Canada & supplied by

BETAC BUILDING CONTRACTING LLC, Dubai, UAE
and installed by
Asia Prime General Contracting Co. LLC
 Section 02
Safety Instruction
The CCU Units and its ancillaries must be installed and serviced by authorized /
experienced personal qualified in HVAC system installation and maintenance.
Improper installation will create an electrical hazard which could result in death (or)
serious injury, for installers (or) others, due to electrical shock and may also cause
damage to property.

RISK OF ELECTRICAL SHOCK OR ELECTRICUTION

Before removing the terminal box cover and before any removal-dismantling of the
HVAC equipment, make sure that the electricity supply has been switched off.

The equipment and motor must be grounded.

Make sure that the motor is suitable for the electricity supply on which it will be used.
The operating voltage and frequency are stated on the motor nameplate must be
matching with the supplied power.

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Section 03
Warning
 WARNING
DO NOT ATTEMPT TO OPERATE OR CARRY OUT MAINTENANCE ON ANY SYSTEM OR
PART THEREOF UNLESS QUALIFIED AND AUTHORISED.

WARNING
DO NOT OPEN OR TOUCH ANY LIVE ELECTRICAL CONTROL PANEL OR TERMINAL BOX
UNLESS QUALIFIED AND AUTHORISED

WARNING
DO NOT TURN OFF ELECTRIC MOTORS ONLY AT THE POWER ISOLATING SWITCH.
ALWAYS USE THE CONTROL ISOLATOR AND THEN ISOLATE AT THE MOTOR
ISOLATOR.

WARNING
DO NOT MODIFY OR ALTER ANY PART OF THE CONTROL CIRCUIT WITHOUT
AUTHORISATION.

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 Section 04
Training Module
Ensure that all staff, technicians and workers performing any repairs,
replacements or maintenance are adequately trained in the technical and safety
aspects of the mechanical, electrical, plumbing or fire protection equipment and
systems prior to allowing the works to commence.
Further Information and additional instructions for a complete understanding of
the operation and maintenance characteristics of the building services are given in
the Operation and Maintenance Manuals.
All staff, technicians and workers must undergo a site induction to identify the site
working conditions, site environment, site safety requirements and site
orientation for emergency evacuations.
Section 05
System
Description
 The installed CCU units at the IT server room for the HVAC Units are designed to a
high engineering standard to provide the requirements of ventilation, heating,
cooling, and air distribution to the complete server room as well as inside the raised
floor also.

The below closed control Units (CCU) are installed in the IT server room,

 Unit Ref. # CCU-OFF-01 DX UNIT Model # GAD15

 Unit Re. # CCU-OFF-02 DX Unit Model # GAD15

The Capacity of units are 15 KW cooling each.

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Section 06
Operation
Procedures
The Following points must be taken before the startup operation.
 Before the operation, the indoor unit and outdoor unit must installed
properly.
 The refrigerant pipe system must completely connected and leak proof.
 The wiring must be completely connected
 The ground wiring has been connected correctly.
 The power voltage fits the rated voltage of the unit air conditioner.
System Start-up:
 Before beginning start-up operation, the startup personnel should familiarize
themselves with the unit, options and accessories, and control sequence to
understand the proper system operation. All personnel should have a good
working knowledge of general start-up procedures and have the appropriate
start-up guides available for consultation. The initial step in any startup
operation should be a final visual inspection.
(Continue......

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All equipment and piping should be inspected to verify that the systems are
complete and properly installed and mounted, and that no debris or foreign
articles such as paper or drink cans are left in the units or other areas. A clean
filter of the proper size and type must also be installed. Failure to do so could
result in damage to the equipment and/or void all manufacturers’ warranties.
 Section 07
Maintenance
Procedures
The Canatal G Series Closed Control Unit (CCU) employs carefully selected
components of proven quality to ensure prolonged trouble-free operations.
Maintenance-free solid-state controllers also enhance the reliability of the whole
system.

The CCU equipped with microprocessor controller to control and monitoring

functions which makes the machine user friendly and simplifies maintenance
routine and fault-finding procedure. The maintenance practice which are given
below are for guidance only and are for general service and maintenance to
minimize wear and are given below are for guidance only and are for general
service and maintenance to minimize wear and tear resulting from normal
operation and for insurance that the machine will be operating under the most
efficient condition.
The Maintenance is classified into two categories, i.e. general service and
preventive maintenance. General Service, including regular inspection may be
carried out by technician of the client. Preventive maintenance however must be
performed by competent service personnel familiar with the servicing of air-
conditioning, electrical and electronic engineering equipment. Although the
status of the machine and the environmental conditions are under the constant
surveillance of the controller and any abnormality will be announced either as
out-of-limit warning or alarm, there is, however no place for complacency if
efficient and reliable service is demanded from these well engineered machines.
Regular inspection
 The machine should be inspected periodically to ensure that no unusual
noise or changes in operation are present. Any abnormalities should be
investigated immediately by qualified air-conditioning personnel.
Preventive Maintenance
 Replace all filters.
 Clean evaporator coils and condensers.
 Clear clogs and clean drain lines to ensure proper flow.
 Remove any standing water from drain pans to avoid overflows.
 Replace worn pulleys and belts.
 Check the refrigerant charge and for any possible leaks.
 Check Microprocessor and their controls to ensure they are correctly set.
 If necessary, change batteries of the microprocessor.
 Check all connections and the electrical system.
 Make sure the fan motor is operating correctly.
 Inspect the blowers and blades to maintain proper airflow.
 Lubricate any moving parts.
 Make sure the CCU cabinet door is securely closed.
 Remove any debris from around the unit if it is outdoors.
General maintenance of Units includes the following points:-

 Keep Units clean and free of rust.

 Check and replace the filter as required.
 Check condition of flexible connection and repair / replace as necessary.
 Check guards and other safety features for satisfactory condition and security.
 Inspect anti vibration supports at intervals given in the maintenance
schedules.
 Check for vibration due to out of balance.
 Check for unusual noises.
 Inspect V belt drives at intervals given in the maintenance schedule.
 Lubricate bearings as necessary. It is preferable to add grease while the shaft
rotates slowly.
 Check electrical control panel and its components.
 TROUBLE SHOOTING
Malfunction
Constant excessive bubbling of
coolant inthe inspection glass
Filter dryer iced up
Insufficient humidification
Cause Solution
Check all connections for leaks
and tighten valves with a torque
Too little coolant wrench,
Check coolant quantity and
refill, ifnecessary
Nozzle needle in injection
Replace the injection valve
valve isstuck
Filter dryer exhausted Replace the filter dryer
See table in Chapter 7, "Unit
Fault on humidifier
Components"
Humidity controllerset
Reset
incorrectly
 TROUBLE SHOOTING
Malfunction Cause
Miniature circuit- breaker has
beentriggered
No power supply on heater coils
Heating rod defective (power
No heating (electric heater)
supply on heatingcoils present)
Temperature limiterhas been
triggered
Solution
Check and switch on, when
necessary
Check the controller
Check the over temperature
protectiondevice
Replace the heating rods
Rectify the cause of the trigger
(e.g. power failure, insufficient air
quantity, fan failure, cover not fully
open, volumetric flow fluctuations)
and reset the temperature limiter
 Malfunction
No air flow/To little air
Motor power consumption too high
Cause Solution
Check position of the main switch
Check the system controller
(externalrelease)
Check the motor protection and
switch back on, if necessary
Check the power supply on all three
motorphases
Measure the power consumption
Fan not moving Check the motor winding. Replace
the motor in the event of phase-to-
phase faultsor earth faults.
Check the motor protection device
(thermalcontact)
Check the controller
Check the air flow monitoring
Check the setting values on the
pressuresensor
Too much air flow Set the air flow
Wrong direction of motor rotation Phase change on mains connection
External pressure inraised floor too
Check the pressure
high
 Thermostat not switched to cooling
Motor-circuit breaker has been
triggered
High-pressure switch has been
switched off
Compressor is not running
To little coolant, low-pressure
switch does not switch
Control lines of thecontactor
interrupted
Contactor coil burntout
Set the thermostat correctly
Check the settings and measure the
motorwinding, if necessary
Reset the pressure switch and
replace, ifdefective
Check the condenser for
contamination andclean, if
necessary
Check the correct activation
See cooling circuit
Check the screws, terminals and
cables
Replace the coil

Condensate discharge blocked
Discharge of water
Heat exchanger orpipes are
leaking
Valve does not open
No cooling output
No cold water
Air in the exchanger
Clean the tray and
drainCheck the ball
siphon
Check for damages and tightness of
screw connections
Check the controller (setpoint)
Check the valve position
Check the generation of cold water
Bleed the exchanger
Tools, Equipment & Safety:

 All tools and equipment should be kept clean and in good condition. They
should be regularly inspected and any signs, which show excessive, wear or
defect, should be replaced immediately.
 The following are a few notes on the use of tools and equipment:
 Only use each tool for purpose of which it was designed
 Never leave tools lying about. Collect them when finished and return them to
correction location
 Use Calibrated instruments

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Cautions:
 Never leave an enclosure door open unnecessarily, especially in a dust
environment.
 Never switch on the MCCB after a trip without having located and corrected
the fault
 Never reset an overload relay without having found and eliminated the cause
of the fault.
 Never Adjust the current settings of MCCB's, Overload relays and Earth
leakage relays.
 Never Remove shrouds of live parts
 Never modify a part or replace with a poorly matched spare.

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Section 08
Emergency
Contact
Supplier:
BETAC BUILDING CONTRACTING LLC
OFFICE 2209, SIT TOWER
DUBAI SILICON OASIS, DUBAI
UAE
Tel: + 971 55 120 1975
Email: sales@betac.ae
Contractor:
Asia-Prime General Contracting Co. LLC
P.O. Box 3346,
Sharjah, UAE
Telephone: +971 657 42226
Fax: +971 65744848
Email: info@asia-prime.com
Website: www.asia-prime.com
 QUESTIONS ARE WELCOME
PLEASE SIGN OFF THE ATTENDANCE SHEET

THANKS

-----END OF TRAINING PRESENTATION -----