FAMILARITY

with
SHOP FLOOR ACTIVITIES
V. Srinivasan M.E.
Management Probationer
(R & D)

K. Vijay Raghavan B.E.
Graduate Engineering Trainee
(Quality)

By

&
What is the company about..?
ETA Engineering Pvt. Ltd. is a subsidiary of Electromechanical Technical
Associates Ltd, owned by Emirates Trading Agency LLC, Dubai, which is
part of Dubai-based industrial conglomerate, the ETA Group, which includes
the ETA-ASCON Group of companies and the ETA-Star Group of
companies.
The company is having its registered office in Chennai and Branch offices at
Ahmedabad, Bengaluru, Bhopal, Chandigarh, Chennai, Delhi, Hyderabad,
Jaipur, Kochi, Kolkata, Mumbai, Mysore & Pune.
It is the only Indian Manufacturer of Air Handling Units to achieve
prestigious Eurovent Certification. It is one of the 6 Companies Globally to
achieve UL Accreditation for its AHUs. It produces Cooling & Heating
Coils which are ARI Certified. The manufactures CE Certified Ducted
Splits.
The Entire Company is certified for ISO 9001: 2008 by LRQA.
ETA Engineering is also a founding member of Indian Green Building
Council (I.G.B.C).
2
What the company manufactures?
The Company manufactures & markets full range of Air-conditioning
products including:
Air-Cooled & Water cooled Scroll Chillers,
Air Handling Units,
Ducted Splits,
Fan Coil Units,
Floor Mounted Packaged &
Unitary type Self Contained Packaged Air conditioners.

These are ideally suitable for installation in applications such as Bank,
Hospitals, Office premises, Shopping/ Commercial Complexes, Restaurants,
Retails outlets etc.

3
Classification of Manufactured Product
DX
Chiller
FMPAC
RTPU
Ductable split
ODU
IDU
Chilled Water
AHU
FCU

4
Air Handling Units
ETA began its Air Handling Units manufacturing in 1999 year under
technical collaboration with Novair, Italy.
The Collaboration was for Five years and it ended on 2004.
Ten years of AHU manufacturing experience from the field and
Indian conditions were adequate for ETA to advance the Art and
Science of AHU Technology through its own Research &
Development.
AMCA Certified blowers are used by ETA for Air Handling Units.
The above certification Guarantee's user the performance of AHU as
per Ratings / Selection Software.
5
Classification of AHUs
Floor Mounted Units
Horizontal Floor Mounted Units
Vertical Floor Mounted Units
Ceiling Suspended Units
Ventilation Units
Exhaust Units
Fresh Air Units
Heat Recovery Units
6
Air-cooled Scroll Chiller
(R-22and R407C)
The Chiller modules are available in wide range of capacities
from 22 to 120 tons:
22, 33, 40, 44, 60, 66, 80, 88 and 120

Chillers have been designed and manufactured to meet the
requirements of tropical climatic conditions and specifically
for outdoor installations.
7
Ducted Split Air Conditioner
(R22 and R 407C)
The Air-cooled Ducted Split Air-conditioner works on scroll
compressor.
The scroll compressor has higher energy efficiency, operates more
silently and is more reliable than the Reciprocating compressor. Scroll
compressors are efficient, quiet and reliable.
Draw Through Airflow Configuration
3 Speed Motors
Rear Return Air Filter
Tonnage in TR: 3, 4, 5.5, 8.5, 11 and 17
8
Packaged Air Conditioner (FMPAC)
(R22 and R 407C)
In Floor Mounted Packaged Air Conditioner the
evaporator along with TEV and compressor are
placed in IDU and condenser alone in ODU.
Air cooled
Tonnage in TR- 5.5, 8.5, 11, 17 and 22
Water cooled
Tonnage in TR- 5.5, 8.5, 11 and 17 (only R22)

9
Roof Top Package Unit (RTPU)
(R-22)
In RTPU the evaporator along with TEV, compressor
and condenser are placed in one single unit (thus the
name Unitary Air Conditioner).

Tonnage in TR- 5.5, 8.5, 11, 17, and 22
10
Fan Coil Unit (FCU)
(Chilled Water )
Tonnage in TR- 1, 1.5, 2 and 2.5.
Both FCU and AHU uses chilled water as
refrigerant in IDU.
Difference lies in the positioning:
in FCU: Return-Filter-Blower-Coil-Supply
in AHU: Return-Filter-Coil-Blower-Supply

11


SHEET METAL SHOP
12
AMADA Turret Punch Press
CNC Controlled programmed by Software AP100 pedal
operated clippers.
Maximum sheet thickness is 3mm
5 axis- X, Y, A, C and T
Xaxis: 1270mm, Y-axis: 2500mm- Max Stroke length=37mm
Press Capacity=200 kN
Features:
Nesting, Repositioning, Nibbling, different dies available
for different material,
45 Tool stations (can accommodate 37 shape tools).
13
Cont..
Die changing- material and thickness
Determination of Clearance




NEX Punch- SARAS Die- Alpha tool guide
Separate grinding machine is provided to remove the
burr off the punch tool.

MATERIAL % OF THICKNESS
Aluminium 15-20
GI ( pre-coated also) 20-25
Stainless Steel 25-30
14
SUTANTRA-Slitting and Shearing Machine
Strip Width= 1250mm (Min Strip Width= 100mm)
Strip Thickness= 0.3 to 1.6mm (GI and Pre-coated).
De-coiler Capacity= 5Ton x 2, feeding at 20m/min.
A series of rollers are equipped in the machine to
navigate a sheet between them.
In which 4 rollers are enabled to slit the sheet at the desired
positions.
All the rollers rotate in direction opposite to the feed i.e. the top
and bottom rollers rotate in opposite directions to each other.
Possible to slit 5 sheets at a time length-wise in one
cycle by adjusting slitting-roller positions.


15
Press Brakes
Cold process and pedal operated and NC controlled.
AMADA
Punch Capacity= 100 kN
Features: wide variety of bending angles, very high accuracy, ram is
stationary and die moves up, goose neck press tools
Thickness capacity= 0.6 to 3mm





HHL
Punch capacity= 110 and 120 kN
Die is stationary and ram moves up


Thickness in mm Die size
0.6-0.8 6 V
0.6-1.2 10 V
1.6-2 12 V
2-3 20 V
16
Shearing machine
HHL make machine for shearing more than 1250mm
till 3000mm.
The job is manually fed and the tool is operated using
a budding pedal.
Notching machine
Corner shearing is called as notching.
For making box shaped sheet metals notches are
made at the four corners.
17
Poly Urethane Foaming (PUF)
To provide thermal and electrical insulation.
Density of foam= 41.6 kg/m
3
Polyol: Iso-Cyanate= 130:166
Totally 19 programs are pre-installed for various quantity of
liquid PUF to be injected depending on the panel geometry.
Curing time 40
o
C for 20 minutes
Quantity of foam required= (Volume of panel)x (Density of
foam)


18
COIL SHOP
19
Fin Press
KLIMA Fin Press -Comaxima Groups.
All kinds of coils varying designs and tonnage
capacities.
Straightening, lubricating, cupping, punching (collar
making), louver making (windowing) and rippling
(wave formation), slitting, shearing and stacking.
Maximum 24 rows and 70 holes along the length.
Decoiler, lubricating oil, material guide, punch press,
fin press mould, suction vacuum blower and scrap
conveyor.
20
Hairpin Bender Machine
KLIMA make NC operated.
Decoiling and feeding, collect clamping, bending and cutting
or only cutting.
3 bends per cycle.
Maximum tube geometry 38.1 x 2mm.
Maximum radius is 1.5mm and 180
o

Maximum fin speed is 1.2 m/s.
Bending is done only for 3/8
th
.
The tube length depends on the TR of the system for which it
has been designed.
The fin length is always less than the tube length.

21
U-Bender Machine
KLIMA make -COMAXIMA group.
Maximum of 6 tubes can be bent per cycle.
The u-bent tubes are small in size used in joining of
the tube ends in the coil grill making.
The diameters of 1/2 and 3/8 are bent.
22
De-burring Machine
The bent tubes are then sent to the de-burring process to
remove the burrs formed.
The plastic balls are used for de-burring utilizing ultra cleaner
solution.
The de-burring process takes place for 20 minutes with
maximum of 40kg/ cycle. The process is repeated till a good
quality of bent tubes are achieved. The 3/8 tubes are provided
with the O-ring for brazing purpose.
The swaging of tube in the grill is provisioned for inserting the
bent tubes and brazing.
23
Lacing
Expander Machines
The process of inserting the copper tube through aluminium fins.
The collars are provided for this purpose in the fins.
It is the process of expanding the diameter of tube within the collar.
The increase of diameter is in range of 0.3mm. There are two types
of expanders:
Vertical and horizontal
Vertical expander is used for only 3/8 tube diameter.
Horizontal expander is used for only 1/2 tube diameter.
Maximum of 4 rows of 48 holes is possible to be expanded in
vertical expander using the rod provided with mandrel and
bullet.
4 tubes are expanded in one cycle in horizontal expander.
24
3D Bending Machine
It is possible to make any
desired shape from a hallow
straight tube using this
machine.
The bent tubes are used to
facilitate the refrigerant flow
among the four components
inside the concealed
structure.
The die is changed depending
on tube diameter.
When tube of length l is to
be bent additional length
equal to BR is added to it.
25
Tube Diameter
(inches)
Bending Radius
(mm)
1/2 20
5/8 35
3/4 40
7/8 50
1 1/8 60
1 3/8 70
1 5/8 80
Headers & Stubs
Headers are the cylinder at the ends of the tubes which
distribute the fluid from the piping to the tubes. And also
collects the return fluid.

Depending on the positioning of the header the coil is
differentiated into LHS and RHS.

Stubs are provided after shrinking (to give a sleeve on one
of edges for easy brazing) to link with the tubes in coil
grill.

Number of holes drilled on the header will commensurate
with the uncovered holes per row.
26
Coil Bending Machine
Coil is bent in case of Ductable Systems for ODUs.
The ODU becomes compact by this process.
After the bending has taken place, the fins are seemed to be
bent over one another. Combing is done in make them
straight.
Leak Check Test
Dry air-350psi- container of water
When leakage is found the brazing process is carried out at
required position.
Leakage in brazing points.
27
Test Labs
Reliability Test Lab
Chiller Test Lab
Psychrometric Test Lab
AHU
Split and Package Units

28
Universal Testing Machine
Used to test the tensile
stress and compressive
strength of materials.

Upto 4.8KN force can be
applied.

Is integrated with a software,
NEXGEN.
29
Conical and Cylindrical Mandrel Test
The Pre-coated GI sheets and
Powder coated panel sheets are kept in
between the conical mandrels and bent
upto 180
o
and checked whether the coats
peel off.

The Pre-coated GI sheets and Powder
coated panel sheets are kept in between the
cylindrical mandrels and bent upto 180
o

and checked whether the coats peel off.
30
Impact Test
A load of 40kg is applied on the test
sheet metal. There should be no peel off on
the area of impact, for a good quality
sheets.
Pencil Hardness Test
The test sheet metal is placed below
the pencil hardness tester. Then the pencil
hardness tester is moved over the sheet
metal. For a good quality sheet metal there
should be no peel off required
31
Hatch Test
The sheet metal is scratched using the
hatch tester and the observed carefully
under light for any peel off.
Thermal Expansion Test
Foams of 50mm and 25 mm thickness are tested.
The test is done for 500hrs at 80
o
C.
There should be no dimensional changes in foam material.
Also the different stickers are checked for peeling under high
temperature.
32
Salt Spray Tester
The different materials are
kept inside the salt spray
chamber for 500hrs.

The chamber temp is
maintained at 36
o
C and bath
temp of 42
o
C.

The materials are kept for
500hrs and checked for any
changes in its dimensional
and physical characteristics
33
ASSEMBLY
Product Flow Path
35
R & D QUALITY
PURCHASE
PRODUCTIO
N
FINAL PRODUCT
Assembly Process
The General Assembly drawings for the system is sent
from the R&D department.
The assembly of unit will be carried out as per the
drawing.
The major four components along with necessary
accessories like the MPD, Filter with drier, Blower for
IDU and Fans for ODU are fixed as per the design.
Refrigerant charging also takes place in the assembly
line.
The system is then subjected to testing for the electrical
and thermal criteria.
36
Cont..
In case of AHUs the assembling process
remains the same except for the dispatching
procedure:
CKD (Complete Knocked Down)
SKD (Semi Knocked Down)
In case of FCU only IDU is assembled.
37
Naming of the Products
38
EX XS XXX X R
ETA
A- Air, W- Water Cooled
Package/ Ductable
Capacity in TR x 12
Evaporator/ Condenser Unit *
A-R134a, C-R407c, R-R22
S-Scroll, R-Reciprocating
*(If both evaporator and Condenser in same system then X is omitted)
Naming of Chillers
39
EX CS XXX R
ETA
A- Air, W- Water Cooled
Chiller
Capacity in TR
C-R407c, R-R22
S-Scroll, X-Screw
Naming of FCU and AHUs
FCU XXX B


Horizontal Floor Mounted AHUs EHF
Ceiling Mounted AHUs ECS
Vertical Floor Mounted AHUs EVF
Ventilation Units AHUs EVE
Energy Recovery AHUs EHU

40
400 x TR + 5
DESIGN ASPECTS
41
42
TUBE DIAMETER
(INCHES)
X
(mm)
Y
(mm)
3/8 25.4 19.02
1/2 31.75 27.5
Y
X
Coil Geometries
(Evaporator & Condenser)
43
F
i
n

H
e
i
g
h
t

FH=X x Tube High
(or) Number of
tubes/row

FL= FPI x no. of Fins

FW=Y x no. of rows
Collar Height Specification
Collars are provided on the fin
to ease the passage of copper
tube through them.
Visually a stack of fin will seem
to have formed a tube.
The collar cracking occurs
resulting in
Actual length < Practical length
The number of fins are
increased for this purpose.
44
FPI Collar Ht (mm)
7 3.62
8 3.17
9 2.82
10 2.54
11 2.30
12 2.11
13 1.93
14 1.81
15 1.69
16 1.58
Copper Tube Size For Header Punch
(Hard Tubes)
Header diameter
(inches)
Wall thickness
(mm)
Stub diameter
(inches)
Collar ID
(mm)
5/8 0.71 3/8 9.72
3/4 1.22 3/8 9.72
7/8 1.22 3/8 9.72
1 1/8 1.22 3/8 9.72
1 5/8 1.22 3/8 9.72
1 2.5 1/2 12.9
1 1/2 2.5 1/2 12.9
2 2.5 1/2 12.9
2 1/2 2.5 1/2 12.9
3 2.5 1/2 12.9
45
3D Bending (Soft Tubes)
Tube diameter (inches) Thickness (mm)
1/4 0.71
3/8 0.71
1/2 0.71
5/8 0.71
3/4 1.22
7/8 1.22
1 1.22
1 1/8 1.22
1 3/8 1.63
1 5/8 1.63
46
Copper Tubing for Swaging
(Soft Tubes)
Tube OD
(inches)
Thickness
(mm)
ID after swage
(mm)
Swage Length
(mm)
1/4 0.71 6.45 15
3/8 0.71 9.625 15
1/2 0.71 12.8 15
5/8 0.71 15.97 20
3/4 1.22 1915 25
7/8 1.22 22.32 25
1 1.22 25.5 30
1 1/8 1.22 28.67 30
1 3/8 1.63 35.02 30
1 5/8 1.63 41.375 30
47
Inspection
Incoming Inspection
Online Inspection
Final Inspection

Different types of tags:
Accepted
Rework
Non-Conformance tag

48
49
DESIGN ASPECTS
General Description
Dimensions
Mechanical Characteristics
Chemical Characteristics
Electrical Characteristics
49
Purchase Part Specification
THANK YOU
50