Free AHU annual service procedure
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Last updated: 2026-04-24 · MapTrack
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What is an AHU annual service?
An AHU annual service is a comprehensive preventive maintenance procedure performed once per year on air handling units. MapTrack helps HVAC teams manage annual services with digital work orders that capture every reading and photo against the asset record. The annual service includes all quarterly service tasks plus deeper inspections such as motor insulation resistance testing full coil cleaning bearing replacement assessment VFD checks and sensor calibration.
Annual AHU servicing is a critical compliance requirement under AS/NZS 1668.2 and state-based WHS regulations. A thorough annual service identifies wear items approaching end of life allows planned replacement during scheduled shutdowns and provides documented evidence that the building HVAC system is safe and performing to design specifications.
Benefits
- Comprehensive coverage: the annual service addresses every component including items not checked quarterly such as motor windings and VFD parameters
- Planned replacements: identifying worn bearings belts and sensors during the annual service allows procurement and scheduling before failure
- Energy performance: coil deep cleaning motor testing and controls calibration restore the AHU to design efficiency
- Compliance evidence: a signed annual service report demonstrates due diligence under the WHS Act and BCA requirements
- Reduced emergency callouts: thorough annual inspections catch developing faults before they cause unplanned downtime
- Asset life extension: proactive replacement of wear items such as bearings and belts extends overall AHU service life by years
Benefits of digitising forms in MapTrack
When you digitise ahu service procedures in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Log refrigerant charge weights and leak-check results against each unit.
- Schedule seasonal changeover inspections tied to heating and cooling cycles.
- Track filter, belt and coil replacement intervals per system.
Book a demo to see digital inspections and forms in MapTrack.
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What to include in an AHU annual service
- All quarterly checks: complete the standard quarterly filter fan coil damper and controls inspection first
- Motor insulation resistance: megger test the motor windings and record insulation resistance values in megaohms
- Bearing assessment: measure bearing vibration velocity and evaluate whether replacement is due at the next service
- Full coil cleaning: chemically clean heating and cooling coils to remove accumulated fouling and restore heat transfer
- VFD inspection: check VFD parameters fault log cooling fan and capacitor condition where fitted
- Sensor calibration: calibrate all temperature humidity and pressure sensors against certified reference instruments
- Condensate system: flush drain pan treat with biocide and verify drain trap seal
- Cabinet and insulation: inspect all panel seals access door gaskets and internal insulation for damage or deterioration
How to complete an AHU annual service
- Complete quarterly service first: perform all standard quarterly checks including filters fan assembly coils dampers and controls before starting annual-only tasks
- Perform motor insulation test: disconnect motor leads and perform a megger test at 500V DC then record insulation resistance and compare to previous year results
- Assess bearings: measure vibration velocity on all fan and motor bearings using a vibration meter and compare readings against ISO 10816 thresholds
- Deep clean coils: apply approved coil cleaner to heating and cooling coils allow dwell time then rinse and verify condensate drainage
- Inspect VFD: review VFD fault history check cooling fan operation inspect DC bus capacitors for swelling and verify all parameters match commissioning values
- Calibrate sensors: compare each temperature humidity and pressure sensor to a certified reference instrument and adjust or flag for replacement
- Document and plan: record all readings and findings compile a list of recommended corrective actions and set the next annual service date
How often should an annual AHU service be performed?
Annual AHU services should be performed once per year typically during a planned building shutdown or low-occupancy period. The annual service builds on top of quarterly servicing so the AHU should receive four services per year in total with the annual service replacing one of the quarterly services.
The Australian WHS Act requires a PCBU to maintain plant so it remains safe for use. AS/NZS 1668.2 provides guidance on ventilation system maintenance frequencies. For critical environments such as hospitals operating theatres and clean rooms manufacturers may recommend six-monthly deep services in addition to the standard quarterly and annual schedule.
Frequently asked questions
- What does an AHU annual service include beyond the quarterly service?
- The annual service adds motor insulation resistance testing, full chemical coil cleaning, bearing vibration analysis, VFD parameter review and fault log check, sensor calibration against certified references, condensate system biocide treatment, and cabinet insulation inspection. It typically takes 4 to 6 hours per unit.
- Can the annual service be split across multiple visits?
- Yes. Some facility managers split the annual service into two visits, completing quarterly checks and coil cleaning on the first visit then motor testing, sensor calibration and VFD inspection on a follow-up. Both visits should be documented as part of the annual service record.
- What qualifications are needed to perform an AHU annual service?
- A qualified HVAC technician with electrical testing competency should perform the annual service. Motor insulation resistance testing requires knowledge of megger testing procedures. Any refrigerant-related work on DX coils requires an ARCTick licence in Australia.
- Is the template free to use without MapTrack?
- Yes. Download and use the AHU annual service procedure for free. Open the file and use your browser Print to Save as PDF. No MapTrack account required.
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