First published February 2009
No part of this publication may be reproduced in any manner whatsoever without permission in writing from the President, Electro Mechanical Projects,
Blue Star Limited.
While due care has been taken to avoid errors or misinterpretation, Blue Star Limited is neither liable nor responsible for consequence of any action taken, on the basis of this publication.
Since ASHRAE standards use the FPS system, FPS nomenclature is used in some places in this publication for convenient reference. Published by Blue Star Limited, Airconditioning Projects Division.
Introduction ... 4
Features of Double Skin Horizontal Floor Mounted AHU ... 6
Technical Data ... 8
Features of Double Skin Vertical Floor Mounted AHU ... 10
Technical Data ... 11
Features of Double Skin Ceiling Suspended AHU ... 13
Technical Data ... 14
Transportation and Storage ... 25
Packing List (typical) ... 27
Double Skin Horizontal AHU Assembly Procedure ... 33
Assembly the AHU ... 35
Recommended Tools ... 50
Electrical Information ... 51
Cooling and Heating Coil Installation ... 52
Condensate Drain Piping ... 54
Air System ... 55
Pre-Start Up ... 56
Operation ... 58
Maintenance ... 59
Wintering System Components ... 61
Removal or Reinstallation of Components ... 62
Installation of Double Skin Vertical AHU ... 64
Installation of Double Skin Ceiling Suspended AHU ... 65
Troubleshooting ... 66
Spare Parts List ... 69
Field Feed Back Card ... 82
Introduction
Double Skin Air Handling Units with Screwless Cabinet
For assured air quality
Blue Star, India’s largest and preferred airconditioning company has been providing expert cooling solutions for nearly six decades. It is with this expertise we bring to you a wide range of air handling units manufactured at our own world-class factories.
The Double Skin Air Handling Unit, as the name suggests has an outer casing made of sandwicthed panels, resulting in low noise, sturdy construction and better thermal insulation. These have been completely redesigned in “Screwless Cabinet” construction. Taper Wedges are used for fixing and locking of the insulated panels with aluminum frame.
Advantages of new ‘Screwless Cabinet’ construction:
• Reliability and Longer Life
Rigid framework comprises an assembly of externally rounded extruded aluminum anodized profiles that are anticorrosive and fiberglass corner joints that avoid condensation at corners. The panels are pressure injected with polyurethane foam, using CFC free R-141 b blowing agent. High and uniform PUF density of 38 ±2 kg/m3 provides better thermal conductivity and sound attenuation properties.
• Better Aesthetics
No gaps and level difference at panel joints. Fixing screws are avoided in assembling panels. The colour of the AHU is texture finish gray.
• High Indoor Air Quality
Double skin panel construction allows easy inspection, cleaning and maintenance of the smooth inner surface, reducing the risk of dirt and bacteria accumulation. There is no erosion of internal insulation material to contaminate the air stream. Improved Panel frame arrangement by overlapping wedge and special gasket reduces air leaks into the casing significantly. This maintains the Indoor Air Quality (IAQ) and also provides the better thermal and acoustic performance.
• Low Noise
Usage of double skin casing, imported AMCA certified fans, anti vibration spring isolators, which isolated the fan from the main structure thus minimizing vibration and results in low operation noise.
• Energy Efficiency
The units utilize Blue Star free flow coils (Coil Nomenclature CDW, CDX, YDW, YDX). The Fins of these coils have a mild ripple, die formed channels to improve heat transfer efficiency and hence are energy efficient.
• Ease of Assembly and Maintenance
New construction leads to faster assembly. The coil is placed on the sliding channel for ease in service and maintenance.
• Reduces Air bypass in Filter Section
New Design of Filter Frame flush with the cabinet minimizes the chance of air leakage between the filter frame and the casing.
• Standard Filter Sizes
The filter sizes are standardized to the internationally recognized standard of four sizes in all horizontal AHUs. The filters are pleated to provide more filtration area.
• Compact Design
Floor Mounted Equipment footprint has been optimized to make the units more compact. Key components like Cooling Coil, Blower Assembly and Filters are redesigned for compact design and better performance.
Double Skin Horizontal Air Handling Units – Floor Mounted Type
The horizontal floor mounted units are ideal units to handle high air quantity. The composite design sections offer both sturdy construction and flexible combination of components such as coils, filters, etc to suit specific applications hence they are widely used in industrial, clean room and large commercial airconditioning. As all major components are aligned to the base tray, it is maintenance and service friendly.
These Double Skin Horizontal Floor mounted Air Handling Units are available in 37 models with air quantity varying from 3250 to 60600 CMH.
Standard features of the Units:
a. Casing
Rigid framework, comprising of smooth, rounded extruded aluminium anodized profiles with fibre glass corner joints.
• Double skin sandwiched panels:
- Outer skin: 0.5 mm pre-painted galvanized sheet steel.
- Inner skin: 0.5 mm plain galvanized sheet steel with 180 GSM Zinc Coating.
• Panels are 24+1 mm thick, pressure injected with polyurethane foam, using CFC-free R-141b blowing agent. Uniform PUF density of 38+/- 2 kg/Cu.m provides better thermal insulation (K factor not exceeding 0.02 W/m-C.)
• Insulated Panels are fixed on the aluminium frame using overlap design wedges. The design avoids use of screws for assembly of panels. 3 mm thick gasket is fixed on frame below the panels. The construction leads to improved air tightness of the cabinet and hence results in better Indoor Air Quality. It also improves the Thermal and Acoustic Performance.
b. Cooling Coils
The Coils are made of ½” Copper tube of thickness 0.36mm and the aluminium fins of thickness 0.12mm. Free flow fin configuration is formed in plain aluminium fin stock with mild ripples die formed channels provide excellent heat transfer capability with low air side Pressure drop. Mechanical expansion of copper tubes with aluminum fins assure good thermal bonding and improve heat transfer. Coils are complete with copper headers provided with air vent and drain plugs. In and out connections are of mild steel for convenience to connect to water line at site.
The coils are placed on sliding channels for ease in service and maintenance.
c. Fans
Fans are of double inlet, double width type with forward curved impeller. The scroll and impeller are made of galvanized steel sheet.
The fans are AMCA certified and are statically and dynamically balanced.
The whole fan assembly is trim-balanced to ISO1940 & AMCA 204 – G2.5 Standard.
Belt-Driven Fans are supplied with three phase, 415V, 50Hz, TEFC squirrel cage Hindustan / Spartan (A batiliboi group of company) make motor with IP55 protection and with Class ‘F’ insulation.
d. Pre-Filters
The Pre filter is 50 mm deep in box type construction of efficiency 90% down to 10 microns confirming to EU – 3 class of EN779 specification. The filter media is synthetic, non-woven fire retardant type.
Pre-filter is pleated to provide more filtration area. The Pleated air filter incorporates a 100% synthetic thermal bonded media with an average arresting exceeding 80% by weight. The filter media is bonded to a metal grid on the air exiting side, Preventing fluttering and maintaining uniformity of the pleats. The filter pack is enclosed in an aluminium frame.
e. Hinges and Handles
The fan section is provided with an access door for ease in serviceability of fan and motor. Nylon handles can be operated from both inside and outside the casing and are user-friendly.
f. View Port and Marine Lamp
View Port is provided on fan door panel which helps to monitor fan and motor status. Marine lamp provides easy visibility. This needs to be electricity connected at site.
g. Limit Switch
Door limit switch automatically trips the motor when the door is opened and hence stop the blower. This needs to be connected up in series with no volt coil of the AHU starter.
h. Damper
Every AHU is supplied with a factory fitted GI, powder coated, opposed blade volume control damper to facilitate air balancing.
Technical Specifications
Length W id th Height Fin Fin Coil Air Qty Fan Model F a n Fan Outlet F a n Motor F a n Motor W ith 4 RD W ith 6 RD Length High Area Opening V elocity Effieiency Power Efficiency Power Coil C oil m m m m m m m m m m Sq.m. CFM CMH Kruger W -m m X m/sec. ηηηηη kW ηηηηη k W Kg. Kg. H m m 1370 900 885 559 635 0.35 1910 3247 K A T10 X 10CM 331 * 289 9.43 63.3% 0.75 61.0% 1.1 200 215 1370 1105 885 7 11 635 0.45 2431 4133 K A T12 X 9CM 309 * 341 10.89 63.4% 1.1 64.5% 1.5 235 250 1370 1105 950 813 699 0.57 3056 5195 K A T12 X 12CM 395 * 341 10.71 62.0% 1.5 60.9% 1.5 245 260 1510 1370 950 1067 699 0.75 4010 6817 K A T15 X 15CM 471 * 404 9.95 64.7% 1.5 63.8% 2.2 340 365 1510 1370 1170 1067 889 0.95 4861 8264 K A T18 X 13CM 430 * 478 11.17 68.6% 2.2 69.2% 2.2 350 375 1670 1510 1200 1168 953 1.1 1 5990 10183 K A T18 X 18CM 557 * 478 10.62 67.3% 2.2 65.8% 3.7 415 445 1670 1715 1200 1372 889 1.22 6470 10999 FDA 450 CM 568 * 568 9.47 64.6% 3.7 62.9% 3.7 425 460 1670 1715 1200 1422 953 1.35 7292 12396 FDA 450 CM 568 * 568 10.67 64.3% 3.7 64.7% 3.7 435 470 2175 1460 1515 1168 1270 1.48 7986 13576 FDA 500 CM 638 * 638 9.26 63.8% 3.7 63.3% 5.5 450 500 1865 1875 1495 1422 1143 1.63 8825 15003 FDA 500 CM 638 * 638 10.24 63.4% 3.7 63.8% 5.5 475 525 1865 1875 1495 1473 1207 1.78 9566 16262 FDA 500 CM 638 * 638 11.1 62.7% 5.5 63.5% 5.5 505 555 2035 1875 1475 1575 1207 1.90 10226 17384 FDA 560 CM 714 * 714 9.47 67.5% 5.5 66.2% 5.5 560 615 2035 2015 1495 1727 1207 2.08 11200 19040 FDA 560 CM 714 * 714 10.37 67.0% 5.5 67.4% 5.5 590 640 2035 2015 1575 1727 1270 2.19 11806 20070 FDA 560 CM 714 * 714 10.93 66.3% 5.5 67.4% 5.5 615 655 2175 2015 1815 1575 1524 2.40 12904 21937 FDA 630 CM 800 * 800 9.55 63.9% 5.5 64.0% 7.5 675 735 2175 2015 1815 1676 1524 2.55 13750 23375 FDA 630 CM 800 * 800 10.14 63.8% 5.5 64.0% 7.5 705 775 2175 2035 1815 1727 1524 2.63 14167 24084 FDA 630 CM 800 * 800 10.45 63.7% 5.5 64.0% 7.5 715 785 2175 2175 1815 1829 1524 2.79 15000 25500 FDA 630 CM 800 * 800 11.07 63.2% 7.5 63.9% 7.5 735 800 2390 2220 1890 1829 1588 2.90 15625 26563 FDA 710 CM 898 * 898 9.15 68.0% 5.5 67.4% 7.5 750 825 2335 2390 1890 1981 1588 3.15 16927 28776 FDA 710 CM 898 * 898 9.92 67.4% 7.5 68.2% 7.5 840 925 2335 2390 1890 2083 1588 3.31 17795 30252 FDA 710 CM 898 * 898 10.42 67.0% 7.5 67.9% 7.5 850 940 2335 2635 1815 2337 1524 3.56 19167 32584 FDA 710 CM 898 * 898 11.23 66.0% 7.5 67.3% 9.3 1060 1150 2540 2635 1890 2337 1588 3.71 19965 33941 F D A 800 T M 1006 * 1006 9.31 64.9% 7.5 64.4% 11 1140 1265 2635 2635 2150 2337 1651 3.86 20800 35360 F D A 800 T M 1006 * 1006 9.7 64.6% 7.5 64.7% 11 1160 1285 2635 2635 2150 2286 1778 4.06 21875 37188 F D A 800 T M 1006 * 1006 10.21 63.7% 9.3 64.9% 11 1180 1300 2635 2635 2150 2337 1842 4.30 23160 39372 F D A 800 T M 1006 * 1006 10.81 63.3% 11 64.7% 11 1200 1325 2700 2635 2205 2337 1905 4.45 23958 40729 F D A 900 T M 1130 * 1 1 3 0 8.86 64.5% 11 61.8% 11 1300 1440 2700 2935 2210 2591 1842 4.77 25300 43010 F D A 900 T M 1130 * 1 1 3 0 9.35 64.9% 11 63.2% 15 1325 1465 2700 2935 2210 2642 1842 4.86 26181 44508 F D A 900 T M 1130 * 1 1 3 0 9.68 64.9% 11 64.0% 15 1340 1480 2700 3000 2150 2692 1842 4.96 26684 45363 F D A 900 T M 1130 * 1 1 3 0 9.87 64.7% 11 64.4% 15 1365 1500 2700 3290 2130 2794 1842 5.15 27650 47005 F D A 900 T M 1130 * 1 1 3 0 10.22 64.3% 11 64.8% 15 1380 1525 2700 3290 2130 2896 1842 5.33 28698 48787 F D A 900 T M 1130 * 1 1 3 0 10.61 63.7% 11 64.9% 15 1400 1540 2700 3290 2130 2946 1842 5.43 29400 49980 F D A 900 T M 1130 * 1 1 3 0 10.87 63.3% 11 64.8% 15 1425 1565 2935 2935 2510 2642 2159 5.70 30694 52180 F D A 1000 T M 1266 * 1266 9.04 65.5% 11 63.1% 15 1465 1590 2935 2935 2510 2642 2223 5.87 31597 53715 F D A 1000 T M 1266 * 1266 9.31 65.8% 11 63.9% 15 1500 1625 2935 3290 2465 2896 2159 6.25 33646 57198 F D A 1000 T M 1266 * 1266 9.91 66.1% 15 65.2% 15 1525 1650 2935 3290 2575 2896 2286 6.62 35625 60563 F D A 1000 T M 1266 * 1266 10.49 65.9% 15 65.9% 18.5 1550 1685AHU Overall Dimension
Standard
Coil
Size
Fan & Motor Details
40mm
TSP
50 mm TSP
al Draw Through Unit
s
Double Skin Floor Mounted Horizont
al Draw Through Unit
s
S
tandard Coil Size
Filter sizes in mm (W X H) Air Qty F in T ube High Coil Area Coil In/Out Coil Circuit 610 X 610 610 X 305 305 X 610 305 X 305 Length Size C F M C M H Inch Sq.Ft. Inch1 4 Row 6 Row Qty 1910 3247 22 20 3.82 1 D C 1 2431 4133 28 20 4.86 1 D C 1 1 3056 5195 32 22 6.1 1 1 1/4 D C 1 1 4010 6817 42 22 8.02 1 1/2 D C 2 4861 8264 42 28 10.21 1 1/2 D C 2 2 5990 10183 46 30 1 1.98 1 1/2 D C 2 2 10-C 6470 10999 54 28 13.13 2 B C 2 2 1 1 7292 12396 56 30 14.58 2 B C 2 2 1 1 7986 13576 46 40 15.97 2 B C 4 8825 15003 56 36 17.50 2 B C 4 2 9566 16262 58 38 19.13 2 B C 4 2 10226 17384 62 38 20.45 2 B C 4 2 1 1200 19040 68 38 22.43 2 B C 6 1 1806 20070 68 40 23.61 2 B C 6 12940 21998 62 48 25.83 2 B C 6 3 13750 23375 66 48 27.50 2 1/2 B C 6 3 14167 24084 68 48 28.33 2 1/2 B C 6 3 15000 25500 72 48 30.00 2 1/2 B C 6 3 15625 26563 72 26+24 31.25 2 1/2 B C 6 3 16927 28776 78 26+24 33.85 2 1/2 B C 6 3 2 1 17795 30252 82 26+24 35.59 2 1/2 B C 6 3 2 1 19167 32584 92 48 38.33 2 1/2 B C 8 4 19965 33941 92 26+24 39.93 2 B C 8 4 20800 35360 92 26+26 41.53 2 B C 12 21875 37188 90 28+28 43.75 2 B C 12 23160 39372 92 30+28 46.32 2 B C 12 23958 40729 92 30+30 47.92 2 1/2 B C 12 25300 43010 102 30+28 51.35 2 1/2 B C 12 26181 44508 104 30+28 52.36 2 1/2 B C 12 3 26684 45363 106 30+28 53.37 2 1/2 B C 12 3 27650 47005 1 1 0 30+28 55.38 2 1/2 B C 15 28698 48787 1 1 4 30+28 57.40 2 1/2 B C 15 29400 49980 1 1 6 30+28 58.40 2 1/2 B C 15 30694 52180 104 34+34 61.39 2 1/2 B C 12 4 3 1 31597 53715 104 36+34 63.19 2 1/2 B C 12 4 3 1 33646 57198 1 1 4 34+34 67.29 2 1/2 B C 15 5 35625 60563 1 1 4 36+36 71.25 2 1/2 B C 15 5
Vertical Double Skin Air Handling Units
Vertical Air Handling Units are designed to occupy lesser floor space than the horizontal units. These units are preferred when floor space is a constraint. They are available in 10 models with airflow ranging from 3500 CMH to 30280 CMH and an external static pressure at 12 mm and 20 mm. These are predominantly used for applications where multiple units are required to aircondition a floor constrained by ceiling heights; duct sizing, floor space etc.
Air Handling Unit WIDTH HEIGHT Coil Det ails Coil Air Qty . Fan Model F a n F a n Operating Wt. Area Opening Outlet Motor kW (Approx.) FL FH V elocity W it h 4 R D W it h 6 R D Coil Coil mm mm mm mm Sq.m CFM CMH Dia. in W -mm X M/Sec 1 2 m m 2 0 m m K g . K g . H-mm ESP ESP 1032 1283 762 508 0.39 2083 3542 K A T 10/10SL 331*289 - 1# 10.28 0.75 1.1 190 205 1388 1349 1 1 1 8 508 0.57 3056 5194 K A T 12/12SL 395*341 - 1# 10.71 1.1 1 .5 225 245 1591 1525 1321 572 0.75 4063 6906 K A T 15/15SL 471*404 - 1# 10.08 1.5 2 .2 330 360 1763 1852 1473 762 1.12 6042 10271 K A T 18/18SL 557*478 - 1# 10.72 2.2 3 .7 395 435 2220 1892 1930 762 1.47 7917 13458 K A T 15/15S2L 471*404 - 2 # 9.82 3.7 3 .7 470 520 2728 2009 2438 762 1.86 10000 17000 K A T 18/13S2L 430*478 - 2 # 1 1.49 3.7 5 .5 560 610 2932 2009 2642 826 2.18 1 1736 19951 K A T 18/18S2L 557*478 - 2# 10.41 5.5 5 .5 590 650 2932 2244 2642 1016 2.68 14444 24556 FDA 450C2M 568*568 - 2 # 10.57 5.5 7 .5 670 745 3164 2372 2794 1080 3.02 16233 27595 FDA 500C2M 638*638 - 2# 9.42 5.5 7 .5 750 815 3466 2372 3048 1080 3.29 17708 30104 FDA 500C2M 638*638 - 2# 10.27 7.5 7 .5 850 950
AIR QTY . F in T ube COIL COPPER M S COPPER M S Length High AREA COIL NOMENCLA TURE HEADER CONNECTO R COIL NOMENCLA T U R E HEADER CONNECTO R SIZE SIZE SIZE SIZE CFM CMH Inch FT² 4 Rows Deep Inch Inch 6 Rows Deep Inch Inch 2083 3539 30 16 4.17 C D W -12-A-4-H-D-16-L/R-30-L 1 1 /8 1 C D W -12-A-6-H-D-16-L/R-30-L 1 1 /8 1 3056 5190 44 16 6.1 1 C D W -12-A-4-H-D-16-L/R-44-L 1 3 /8 1 1 /4 C D W -12-A-6-H-C-16-L/R-44-L 1 3 /8 1 1 /4 4063 6901 52 18 8.13 C D W -12-A-4-H-C-18-L/R-52-L 1 3 /8 1 1 /4 C D W -12-A-6-H-C-18-L/R-52-L 1 3 /8 1 1 /4 6042 10263 58 24 12.08 C D W -12-A-4-H-C-24-L/R-58-L 1 5 /8 1 1 /2 C D W -12-A-6-H-C-24-L/R-58-L 1 5 /8 1 1 /2 7917 13448 76 24 15.83 C D W -12-A-4-H-C-24-L/R-76-L 2 1 /8 2 C D W -12-A-6-H-C-24-L/R-76-L 2 1 /8 2 10000 16987 96 24 20.00 C D W -12-A-4-H-B-24-L/R-96-L 2 1 /8 2 C D W -12-A-6-H-B-24-L/R-96-L 2 1 /8 2 1 1736 19936 104 2 6 23.47 C D W -12-A-4-H-B-26-L/R-104-L 2 1/8 2 C D W -12-A-6-H-B-26-L/R-104-L 2 1/8 2 14444 24536 104 3 2 28.89 C D W -12-A-4-H-B-32-L/R-104-L 2 5/8 2 1/2 C D W -12-A-6-H-B-32-L/R-104-L 2 5/8 2 1/2 16233 27574 1 1 0 3 4 32.47 C D W -12-A-4-H-B-34-L/R-1 10-L 2 5/8 2 1/2 C D W -12-A-6-H-B-34-L/R-1 10-L 2 5/8 2 1/2 17708 30080 120 3 4 35.42 C D W -12-A-4-H-B-34-L/R-120-L 2 5/8 2 1/2 C D W -12-A-6-H-B-34-L/R-120-L 2 5/8 2 1/2
Air Handling Unit
ails FLA T FIL TER SIZE (48mm THK.) F IL T E R W H W H W H W H W H W H W H W H Area 600 500 600 600 500 600 600 400 400 600 500 500 500 400 400 500 FT² 2 4.3 2 6.5 2 1 9.0 6 12.9 8 17.2 8 20.7 4 6 23.3 4 6 29.1 10 32.3 6 6 35.5
Ceiling Suspended Units
These units as the name suggests should be suspended from the ceiling thus requiring no floor space. These units are ideal for commercial application where floor space is at a premium. As they are compact and can be tucked away above the false ceiling, they find a place inside the conditioned area itself. Thereby reducing installation costs and also remains unobtrusive giving flexibility to the design of the interior. Panels are fixed to the framework by wedges thus avoiding usage of screws. They are available in 18 models with air quantity ranging from 1770 CMH to 13568 CMH and an external static pressure range of 12 mm and 20 mm.
The three models DCWSL-035,DCWSL-050 & DCWSL-070 are available in both direct driven with 3 speed single phase motor or belt driven with 3 phase motor and the other AHUs are available in belt driven models only.
AHU-T
echnical S
pecification
y p e Coil Fan Outlet W ith 4 RD W ith 4 RD L W H F L F H Area Air Quantity Fan Model Fan Opening V elocity 1 2 m m E S P Size Q ty Coil Coil mm mm mm mm mm Sq. Mt C F M C M H Kruger W -mm * H-mm m /s Motor Kw . W -mm * H-mm # K g . K g . 908 1238 556 965 381 0.368 1979 3365 KDD10-10 SL 331 * 289 - 1# 9.77 0.55 500 * 400 2 165 180 948 1743 556 1473 381 0.561 3021 5135 KDD10-08 S2L 265 * 289 - 1# 9.31 0.55 500 * 400 3 195 215 1048 2200 556 1930 381 0.735 3958 6729 KDD10-10 S2L 331 * 289 - 1# 9.77 0.55 500 * 400 4 290 310AHU Overall Dimensions (Fan, Coil, Prefilter)
S
tandard Coil Size
Fan & Motor Det
ails Pre Filter (50mm thick.) Operating Wt. Fan L W H F L F H Coil Air Quantity Fan Model Fan Opening Outlet Motor Motor Size Qty W ith 4 RD W ith 4 RD Area V elocity Power Power Coil Coil m m m m m m m m m m Sq. Mt C F M C M H Kruger W -mm * H-mm m /s kW kW -m m * H-mm # K g . K g . 908 784 556 508 381 0.194 1042 1770 K A T 9 7 S L 232 * 262 - 1# 8.09 0.55 0.55 600 * 400 1 1 5 0 1 7 0 908 1238 556 762 381 0.290 1563 2655 K A T10-8 SL 265 * 289 - 1# 9.64 0.55 0.75 500 * 400 2 1 7 5 1 9 5 908 1238 556 965 381 0.368 1979 3362 K A T10-10 SL 331 * 289 - 1# 9.77 0.75 1.1 500 * 400 2 1 9 0 2 0 5 948 1743 556 1219 381 0.465 2500 4250 K A T 9 7 S 2 L 232 * 262 – 2 # 9.71 1.1 1.1 500 * 400 3 2 1 5 2 3 0 948 1743 556 1473 381 0.561 3021 5135 K A T10-8 S2L 265 * 289 – 2 # 9.31 1.1 1.5 500 * 400 3 2 2 5 2 4 5 1048 2200 556 1727 381 0.658 3542 6021 K A T10-8 S2L 265 * 289 – 2 # 10.92 1.5 1.5 500 * 400 4 3 2 0 3 4 8 1048 2200 556 1930 381 0.735 3958 6729 K A T10-10 S2L 331 * 289 – 2 # 9.77 1.5 2.2 500 * 400 4 3 3 0 3 6 0 1048 2130 662 1676 508 0.852 4583 7791 K A T12-9 S2L 309 * 521 – 2 # 10.27 2.2 2.2 400 * 500 1 3 4 5 3 8 0 500 * 500 3 1048 2130 662 1829 508 0.929 5000 8500 K A T12-9 S2L 309 * 521 – 2 # 11.20 2.2 2.2 400 * 500 1 3 6 0 4 0 0 500 * 500 3 1099 2097 810 1778 572 1.016 5469 9297 K A T12-12 S2L 395 * 341 – 2 # 9.59 2.2 3.7 610 * 610 3 3 8 5 4 2 5 1099 2097 810 1727 635 1.097 5903 10035 K A T12-12 S2L 395 * 341 – 2 # 10.35 2.2 3.7 610 * 610 3 3 9 5 4 3 5 1149 2333 810 1880 635 1.194 6424 10913 K A T 15-1 1 S2L 373 * 404 – 2 # 10.06 2.2 3.7 305 * 610 1 4 1 5 4 4 5 610 * 610 3 1149 2333 810 2032 635 1.290 6944 11798 K A T 15-1 1 S2L 373 * 404 – 2 # 10.88 3.7 3.7 305 * 610 1 4 2 5 4 6 0 610 * 610 3 1149 2638 810 2184 635 1.367 7465 12683 K A T 15-15 S2L 471 * 404 – 2 # 9.26 3.7 3.7 610 * 610 4 4 4 0 4 7 5 1149 2638 810 2337 635 1.484 7986 13568 K A T 15-15 S2L 471 * 404 – 2 # 9.91 3.7 3.7 610 * 610 4 4 5 0 49 5
AHU Overall Dimensions
S
tandard Coil Size
F a n & Motor Det ails P re Filter (50mm th ic k .) 12mm ESP 20mm ESP Operating Wt. (Approx.) y p e
Fin T u b e Coil Copper MS Copper MS Length High Area Coil Nomenclature Header Connecto r Coil Nomenclature Header Conenctor Size Size Size Size C M H Inch FT² 4 Rows Deep Inch Inch 6 Rows Deep Inch Inch 1771 20 12 4.17 C D W -12-A-4-H-D-12-L/R-20-L 1 1 /8 1 C D W -12-A-6-H-D-12-L/R-20-L 1 1 /8 1 2657 30 12 6.1 1 C D W -12-A-4-H-D-12-L/R-30-L 1 1/8 1 C D W -12-A-6-H-D-12-L/R-30-L 1 1/8 1 3364 38 12 8.13 C D W -12-A-4-H-D-12-L/R-38-L 1 1 /8 1 C D W -12-A-6-H-D-12-L/R-38-L 1 1 /8 1 4250 48 12 12.08 C D W -12-A-4-H-C-12-L/R-48-L 1 1/8 1 C D W -12-A-6-H-C-12-L/R-48-L 1 1/8 1 5136 58 12 15.83 C D W -12-A-4-H-C-12-L/R-58-L 1 1/8 1 C D W -12-A-6-H-C-12-L/R-58-L 1 1/8 1 6021 68 12 20.00 C D W -12-A-4-H-B-12-L/R-68-L 1 3/8 1 1/4 C D W -12-A-6-H-B-12-L/R-68-L 1 5/8 1 1/2 6729 76 12 23.47 C D W -12-A-4-H-B-12-L/R-76-L 1 3/8 1 1/4 C D W -12-A-6-H-B-12-L/R-76-L 1 5/8 1 1/2 7791 66 16 28.89 C D W -12-A-4-H-B-16-L/R-66-L 1 5/8 1 1/2 C D W -12-A-6-H-B-16-L/R-66-L 1 5/8 1 1/2 8500 72 16 32.47 C D W -12-A-4-H-B-16-L/R-72-L 1 5/8 1 1/2 C D W -12-A-6-H-B-16-L/R-72-L 1 5/8 1 1/2 9297 70 18 35.42 C D W -12-A-4-H-B-18-L/R-70-L 1 5/8 1 1/2 CDW -1 2-A-6-H-B-18-L/R-70-L 1 5/8 1 1/2 68 20 38.37 C D W -12-A-4-H-B-20-L/R-68-L 1 5/8 1 1/2 C D W -12-CA-6-H-B-20-L/R-68-L 1 5/8 1 1/2 74 20 41.32 CDW -12-A-4-H-B-20-L/R-74-L 2 1 /8 2 CDW -12-A-6C-H-B-20-L/R-74-L 2 1 /8 2 1805 80 20 44.27 C D W -12-A-4-H-B-20-L/R-80-L 2 1/8 2 CDW -12-A-6-H -B-20-L/R-80-L 2 1/8 2 86 20 47.22 C D W -12-A-4-H-B-20-L/R-86-L 2 1/8 2 C D W -12-A-6-H-B-20-L/R-86-L 2 1/8 2 92 20 50.17 C D W -12-A-4-H-B-20-L/R-92-L 2 1/8 2 C D W -12-A-6-H-B-20-L/R-92-L 2 1/8 2
AHU - Coil Det
½” CDW / CDX Coils: Nomenclature
1. CDW Water Cooling Coils:
Comfort ½” Water Cooling Coil
Fins per Inch, 12 FPI
Fins Material, A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H: Horizontal
Circuiting (Tubes per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand, R: Right, L: Left
Finned Length (FL), 26” to 114”
L: Loose
Note: Field to specify (a) Circuit type: B. C. D; (b) Hand-off connection: LHS, RHS.
Coil Specifications: ½” OD Copper tube, Tube thinkness 0.36mm, Fin thickness: 0.12mm Aluminium fins.
2. CDX Direct Expansion Cooling Coils:
Comfort ½” Direct Exp.
Fins per Inch, 12 FPI
Fins Material A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H: Horizontal
Circuiting (Tuber per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand. R: Right, L: Left
Finned Length (FL), 26" to 114"
L: Loose
Total Coil Load in MBH, 1 MBH = 1000 BTU/HR
Suction Temp., Deg. F
Tubes per Circuit, B=4, C=6, D=8
No. of Circuits
Note: Field to specify (a) Circuit type: B. C. D; (b) Hand-off connection: LHS, RHS.
Coil Specifications: ½” OD Copper tube, Tube thinkness: 0.36mm, Fin thickness: 0.12mm Aluminium fins.
Double Skin Horizontal Floor Mounted ('E' Family)
Design:
Computerised selection
AHU selection software is used for optimal model selection for customised needs. The selection software provides the following information:
• Overall dimensional details • Technical Data Sheet • Sections selected • GA Drawing
• Details of Individual sections • Costing Sheet
Casing
Rigid framework, comprising of externally chamfered extruded aluminum anodised profiles, with fibre glass corner joints.
• Double skin sandwiched panels :
Inner Skin : 0.5mm plain galvanized sheet confirming to IS 277.
Sheet options : 0.6mm GP, 0.8mm GP, 1.0mm GP, 1.2mm GP, 0.9AI, 1.2mm Al,
0.6mm SS(304), 0.8mm SS(304).
Outer Skin : 0.5mm pre-painted galvanised sheet.
Sheet options : 0.6mm PP, 0.8mm PP, 1.0mm PP, 0.9mm AI, 1.2mm Al, 0.6mm SS-304,
0.8mm SS-304.
• Panels are pressure injected with polyurethane foam, using CFC-free R-141b blowing agent. High and uniform PUF density of 38+ 2Kg/m3 provide better thermal insulation “K” factor (not exceeding 0.02 Watt / MC) and
sound attenuation properties. The following options can be selected based on customer requirement.
• Option 1: Panels of 24+ 1mm thickness with standard aluminum extrusions and fiberglass corner joints.
• Option 2: Panels of 46+ 1mm thickness with “internally coved” thermal break aluminum extrusions and
fiberglass corner joints. Recommended for total static pressure above 85 mm and these AHUs are suitable for outdoor installation.
• Panels are fixed to frame with tapered wedges inserted in aluminum extrusions. The gaskets have stable thermal conductivity and less water vapour permeability.
• Fan and motor are mounted on aluminium extruded slide rail base frame. It is isolated from main casing by using vibration isolators (using 15mm nominal deflection). To arrest vibration, fan outlet is connected to the AHU casing using fire and moisture resistant canvas.
• Hinged service door in fan section provides easy access to fan and motor. View port is provided on fan door panel to help to monitor fan and motor status. Marine lamp provides easy visibility. Door limit switch automatically trips the motor when the door is opened and hence stop the blower.
• Drain pan with differential slope assures quick and complete water drainage ensuring high Indoor Air Quality (IAQ). Drain Pan is 80mm deep and fabricated from 0.8 mm thick GI Powder Coated and optional 1.25mm
• AHU is supplied with factory fitted GI, powder coated, opposed blade volume control damper to facilitate field balancing.
• Aluminium die cast powder coated hinges provide adequate strength to the door. Nylon handles can be operated from both inside and outside the casing and are user friendly.
Cooling Coils
Free flow fin configuration formed by mild ripples and die formed channels provide excellent heat transfer capability with low air pressure drop. Mechanical expansion of copper tube with aluminium fins assures tight bonding, providing optimum heat transfer. Coils are complete with copper headers.
Water or Direct Expansion coils can be selected based on requirement. Water coils are self draining and vented type. Design working pressure is 250 psig. at 300°F.
The following options of sectional length can be selected based on requirement: • Coil Section up to 6 Row Deep
• Coil Section up to 8 Row Deep
• Cooling Coil 6 Row Deep and Heating Coil 2 Row Deep • Cooling Coil 8 Row Deep and Heating Coil 2 Row Deep
Fans
Fans are imported, AMCA certified, energy efficient, with double inlet, double width, forward or backward curved impeller. All wheels are statically and dynamically balanced. Fan bearings are self-aligning, pillow block or flanged type regreasable ball bearings. The scroll and impeller are made of galvanised steel sheet. The fan is V-belt driven through a 3 phase, 415V±6%, 50 Hz AC, squirrel cage, TEFC induction, 4 Pole, IP55, Class ‘F’ motor. AHUs with static pressure requirement of more than 85mm are suggested with backward curved impeller.
Pre Filters (50mm thick)
Pre Filters are pleated to provide more filtration area. The filters are of the cassette type. The filter media are of the synthetic non-woven type, supported with aluminium and HDPE mesh and generally conforming to EU-3 of EN-779 specifications. Filter efficiency is 90% down to 10 micron. Filters are provided with handles for easy removal.
Mixing Box / Inlet Section (Optional)
Section is designed for interconnecting return air and fresh air. The following options can be selected based on requirement:
• Mixing Box section with one Return Air Damper and Pre Filters • Mixing Box section with one Fresh Air Damper & Pre Filters.
Fine / Bag Filter Section (Optional)
Section is designed for 300/500/600mm deep Fine filters or Bag filter with 25 mm flange.
The filters are arranged vertically in the specially designed heavy-duty galvanized sheet steel frame to avoid air bypass and are removable from front. Filters are mounted on frame with positive clamping arrangement. Filter section is provided with access door panel, with aluminum die-cast powder coated heavy duty hinges and nylon handles with positive locking. The handle can be operated from both ends for ease in serviceability.
HEPA Filter Section (Optional)
Section is designed for 300mm deep HEPA Filters with 25 mm flange.
The filters are arranged vertically in the specially designed heavy-duty galvanised sheet steel frame to avoid air bypass and are removable from front. Filters are mounted on frame with positive clamping arrangement. HEPA Filter section is provided with access door panel, with aluminum die-cast powder coated heavy duty hinges and nylon handles with positive locking. The handle can be operated from both ends for ease in serviceability. HEPA Filter should be selected only after Fine or Bag filters.
Combination Filter Section (Optional)
Section is designed for combination of 50mm thick Pre Filters mounted together with Fine / Bag Filters. The filters are arranged vertically in the heavy duty galvanised sheet steel frame and removable from front. Filters are mounted on frame with positive clamping arrangement. Fine / Bag filters can be removed only after the removal of prefilter. All filters are also available in Aluminium flange for phama or clean room application.
Face and Bypass Damper Section (Optional)
Standard face and bypass dampers are of opposed blade type. Face damper is at the bottom in front of the coil, and bypass damper is on the top. Two dampers are interlocked and provide a single control point. The opening size in the frame for mounting the Face damper will be equal to maximum size of coil
Select aluminium damper only for requirement with motorised operation with modulating motor. Motorised actuators are of direct mounting type. It could be two position (on/off) or modulating (input signal 0-10V DC or 4-20mA).
Droplet Eliminator Section (Optional)
To avoid condensate or spray of water carryover into the fan section, suggest use the following droplet eliminator after the coil or spray section:
• 2 Pass GI / PVC Droplet Eliminator • 4 Pass GI / PVC Droplet Eliminator
Humidification Section (Optional)
Celdek type humidification section is provided in AHU for cooling and humidification purpose, this is required in places where the temperature is quite high with low humidity.
8" Cellulose pad should be used to get the saturation efficiency of about 90%.
The droplet eliminator of 4 pass must be provided after the humidification section to avoid any water carry over in the supply air.
Heater Section
Heater section with appropriate capacity of heater should be selected to maintain the RH. These heaters can be provided in number of stages and banks as per the requirement.
Heat Recovery Wheel
Heat Recovery wheel is used in applications where we want to utilize the heating or cooling of the supply air without mixing with the fresh air.
In other words heat recovery wheels are desirable where we want the heat transfer from supply air to the fresh air without the mass transfer.
It is used in fresh air application in double tier arrangement.
Heat recovery wheel is placed before the coil and as it recover some quantity of heat (Cooling) from the supply air, it helps reducing the load on the coil and hence lesser capacity of chiller/condensing unit is required. The effectiveness of the heat recovery wheel is about 75 – 80%.
Heat Pipe
Run around type (Horse shoe type) or vertical heat pipe can be provided in our AHUs.
Run around type Heat Pipe has Pre cooling and Re – Heating coils, connected through the refrigerant piping. The hot air interact with the Pre cooling side of the coil and get cooled, the refrigerant inside the coil get evaporated and get accommodated in the reheating coil.
This pre cooling helps in reducing the load on the main coil and the air after passing through the main coil gets further cooled and is with high RH.
The Re heating side of the coil exchanges the heat with this cooled and high RH Air, and gets converted into liquid form.
This liquid state refrigerant due to gravity gets accumulated in the pre cooling coil.
The Air After passing through the Re-Heating Coil gets heated to maintain the desirable temp. 22-24°C in the room with a moderate RH of 50-60% in the room, which is desirable.
The effectiveness of the heat Pipe is about 45 – 65 %.
The vertical type of heat pipe is used in two tier arrangement, which recovers the sensible heat from return air.
Variable Pitch pulley
VFD
Variable frequency drive can be provided with AHU, which helps in maintaining varying air flow by changing the frequency and thereby Rpm of the motor to maintain the desired conditions. HVAC VFD with inbuilt basic controls can also be provided.
UV emitter
UV emitter is used to improve the indoor Air Quality.
It can be mounted on the coil and hence does not require any extra space to mount.
Activated carbon filter
Activated carbon filter is used to remove the odor from the Air and can be provided in our AHU.
Empty Section
Sections with different lengths are available to suit any specific requirement.
Base Channel
Entire unit is completely supported by a full-perimeter base rail channel. The base rail is constructed of 2mm thick galvanised sheet steel and has intermediate cross member for unit support.
Unit Assembly
Units are despatched ex-factory upto E-500 in Top and Bottom assembled condition, and above that in dismantled condition. The assembly of units will be carried out at site.
Factory Test
Each coil is factory tested and checked for leaks at 325 Psig (pneumatic) under water. Performance Standards are:
In accordance to
• Fans - AMCA 210 • Coils - ARI 410 • Motors - IS-325
• Filter - BS-6540 / ASHRAE 52 - 76
½” YDW / YDX Coils: Nomenclature
1. YDW Water Cooling Coils:
½” Water Cooling Coil
Fins per Inch, 12 FPI
Fin Material A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H: Horizontal
Circuiting (Tubes per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand, R: Right, L: Left
Finned Length (FL), 26” to 114”
L: Loose
Note: Field to specify (a) Circuits1/2" Copper) C. D; (b) Hand-off connection: LHS, RHS (viewing from air entering side) Coil Specifications : ½” OD Copper tube of thickness 0.41 mm with 0.14mm Aluminium fins.
Coils are ½” OD Copper tube of thickness 0.5 mm with 0.15mm Aluminium fins are available as an option.
2. YDX Direct Cooling Coils:
½” Direct Exp.
Fins per Inch, 12 FPI
Fin Material, A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H : Horizontal
Circuiting (Tubes per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand, R: Right, L: Left
Finned Length (FL), 26” to 114”
L: Loose
Total Coil Load in MBH, 1 MBH = 1000 BTU/HR
Suction Temp., Deg. F
Tubes per Circuit, B=4, C=6, D=8
No. of Circuits
Note: Field to specify (a) Tube per circuit; (b) Hand-off connection: LHS, RHS.
Coil Specifications: ½” OD Copper Tube of thickness 0.41mm with 0.14mm Aluminium fins.
Coils of ½” OD Copper Tube of thickness 0.5mm with 0.15mm Aluminium fins are available as an option.
General
This manual is a complete guide for the Installation, Operation and Maintenance of Blue Star's Double Skin Air Handling Units.
Proper installation, operation and maintenance are essential to optimise use of the AHU. The services of a qualified technician from a reputed service company must therefore be employed through a suitable contract to install the AHU.
Transportation & Handling
The Air Handling Units are inspected prior to despatch to ensure that the coil fins, casing panels, exteriors, fan scroll and impeller are in good condition, cross-checked against items ordered, then packed and carefully loaded.
Material Receipt
Carefully inspect all material immediately upon delivery. If any damage is noticed, note the same and inform Factory by telephone, fax or email within one week of receiving the material. Also fill up the Field Feedback Card which accompanies the despatch documents and forward to Factory.
Storage
1. Protect the units from dust and dirt.
2. Do not store internal parts such as fans, motors, cooling coils, etc., in the open. If external parts are stored in the open, ensure that they are well protected against the weather.
3. Do not place sections on top of each another. 4. Do not walk or place weight on top of the units.
5. Do not lean any materials on the units that can damage them, such as panels, aluminum profiles or other external components.
6. Do not store any kind of materials inside sections. 7. Keep the units away from all passageways.
8. Protect protruding parts, coil connection, damper shafts, etc. 9. Place wooden wedges between the units and the ground. 10. Motors must not be stored in damp areas.
11. Filters must be left within packing cartons until ready for installation. 12. Protect fans from debris and dust.
Rigging Instruction
Proper rigging and handling of the equipment is mandatory during unloading and leading the AHU into position. Care must be taken to keep the unit upright during rigging. Avoid unnecessary jarring or rough handling. Proper hoisting straps should be used when rigging (nylon flat rope). It is also mandatory that an experienced and reliable rigger be selected to handle unloading and final placement of the equipment. The rigger must be advised that the unit contains internal components that require to be kept in an upright position. Care must be exercised to avoid twisting of the equipment.
When the equipment is installed in its position, check the following:
1. Check all choke seams and air seals (below fan, motor etc.).
2. Check all door latches and re-adjust if necessary to maintain a good tight seal.
3. Fill up the Field Commissioning Report which accompanies the despatch documents and forward to Factory upon commissioning of the AHU.
CFM : SP : 50
AHU Model :
AHU Tag No. :
Fan Model : 630 CM
Discharge Location :
Coil Connection :
AHU Overall Dimensions (W * H * L) :
ICO No. :
Batch Quantity : 1
Packing List 25mm STANDARD-SKD Condition
Sr. Item Description U.M. CASE SIZE Q/S
No. No.
Puf Panels FAN + COIL SECTION
1 TOP /BOTTOM ASSEMBLY
4 Panel TOP (CUTOUT) No.
4 -A Panel TOP No.
4 -B Panel TOP No.
5 Panel BOT No.
5 - A Panel BOT No.
6 - B Aluminum Extrusion Screwless - Length No.
6 Aluminum Extrusion Screwless - Width No.
7 Aluminum Extrusion Screwless ‘B‘ Type - Width No.
8 - A Aluminum Wedge No.
8 - B Aluminum Wedge No.
8 - C Aluminum Wedge No.
8 - E Aluminum Wedge No.
19 Blower Sssly
19 - A Spring isolator chanel No.
19 - B C - Fabrication No.
19 - C Motor mount No.
19 - D M - 12 Nut plate - 1 No.
19 - E M - 12 Nut plate - 2 No.
20 Base Assly
20 - A Base length - RH No.
20 - B Base length - LH No.
CASE - 1 (Assembled in Top / Bottom
Sr. Item Description U.M. CASE SIZE Q/S
No. No.
20 - D Base Center No.
20 - E Base Corner No.
25 Drain Pan No.
22 Discharge flange Assly (Welded)
22 - A Discharge flange No.
17 Antivibrant Flexible Canvas Connection No.
21 Coil Support No.
33 Motor Base Plate (50mm S.P) No.
34 Spring Isolators - Fan Side Mounting No.
35 Spring Isolators - Near to Motor Set.
36 Spring Isolators - Away From Motor No.
Back, LH and RH panels Case 2
1 Panel LH - DOORNo.
27 Hinges ( Assembled with Door) No.
37 “BLUE STAR“ Logo (FIXED ON DOOR PANEL) No.
1 - A Panel LH No.
1 - B Panel LH No.
2 Panel BACK No.
2 - A Panel BACK No.
3 Panel RH No.
3 - A Panel RH No.
3 - B Panel RH No.
6 - A Aluminum Extrusion Screwless - Height No.
7 - A Aluminum Extrusion Screwless ‘B‘ Type - Height No.
8 - A Aluminum Wedge No.
8 - B Aluminum Wedge No.
8 - C Aluminum Wedge No.
8 - D Aluminum Wedge No.
8 - F Aluminum Wedge No.
Loose Items
9 Blower No.
12 - A Blower Pulley (50mm S.P) No.
10 - A Coil No. case 4
42 Rubber Bush / Washer For Coil Header
-fixed on header. Set.
case 3
Sr. Item Description U.M. CASE SIZE Q/S
No. No.
15 Damper : SA No.
16 Pre Filter : No.
16 - A Pre Filter : No.
Fabrication List
18 Filter frame Assly (Welded)
size
23 Coil Frame Assly
23 - A Coil frame - TOP No.
23 - B Coil frame - LH No.
23 - C Coil frame - RH No.
23 - D Coil frame - BOT No.
24 Spool Assly
24 - A A No.
24 - B B No.
Hardwares
26 Plastic Corner No.
28 Handle No.
29 Marine Light No.
30 Limit Switch No.
31 Hardware Set. Set.
38 Door Switch Bracket. No.
39 PTTJoint (25mm Standard) (FIXED WITH EXTRUSION) No.
14 - A Belt (50mm S.P) - in hardware box No.
40 Stickers Set.
41 Rubber Bush / Washer For Cable Entry Set.
case 6 case 7 case 8 case 9 case 9 case 10
Packing List 25mm STANDARD-CKD Condition
Sr. Item Description U.M. Case Size Q/S
No. No.
Puf Panels FAN + COIL SECTION
1 Panel LH No.
1 - A Panel LH - DOOR No.
2 Panel BACK No.
2 - A Panel BACK No.
3 Panel RH No.
4 Panel TOP No.
4 -A Panel TOP (CUTOUT) No.
4 -B Panel TOP (CUTOUT) No.
5 Panel BOT No.
Aluminium Extrusions
6 Aluminum Extrusion Screwless - Width No.
6 - A Aluminum Extrusion Screwless - Height No.
6 - B Aluminum Extrusion Screwless - Length No.
7 Aluminum Extrusion Screwless ‘B' Type - Width No.
7 - A Aluminum Extrusion Screwless ‘B' Type - Width No. 7 - B Aluminum Extrusion Screwless ‘B' Type - Width No. 7 - C Aluminum Extrusion Screwless ‘B' Type - Height No.
8 - A Aluminum Wedge No.
8 - B Aluminum Wedge No.
8 - C Aluminum Wedge No.
8 - D Aluminum Wedge No.
8 - E Aluminum Wedge No.
8 - F Aluminum Wedge No.
8 - G Aluminum Wedge No.
CFM SP : 50
AHU Model :
AHU Tag No. :
Fan Model : FDA 1000 CM
Discharge Location : UPBLAST
Coil Connection :
AHU Overall Dimensions (W * H * L) :
ICO No. :
Sr. Item Description U.M. Case Size Q/S No. No. Loose Items 9 Blower No. 11 Coil No. 11 - A Coil No. 12- A Motor (50mm S.P) No.
13 - A Blower Pulley (50mm S.P) No.
14 - A Motor Pulley (50mm S.P) No.
15 - A Belt (50mm S.P) No.
16 Damper : SA No.
17 Pre Filter : No.
17 - A Pre Filter : No.
18 Antivibrant Flexible Canvas Connection . No.
Fabrication List
19 Filter frame Assly (Welded)
19 - A Filter frame top No.
19 - B Filter frame side No.
19 - C Filter center support No.
19 - D Spring back down No.
19 - E Spring back up No.
20 Blower Sssly
20 - A Spring isolator chanel No.
20 - B C - Fabrication No.
20 - C Motor mount No.
20 - D M - 12 Nut plate-1 No.
20 - E M - 12 Nut plate-2 No.
21 Base Assly
21 - A Base length - RH No.
21 - B Base length - LH No.
21 - C Base Width No.
21 - D Base center No.
21 - E Base center - 2 No.
Sr. Item Description U.M. Case Size Q/S
No. No.
24 Coil Frame Assly
24 - A Coil frame - TOP No.
24 - B Coil frame - LH No.
24 - C Coil frame - RH No.
24 - D Coil frame - BOT No.
25 Intermediate coil support No.
26 Spool Assly
26 - A A No.
26 - B B No.
27 Drain Pan No.
Hardwares
28 Plastic Corner No.
29 Hinges (Assembled with Door) No.
30 Handle No.
31 Marine Light No.
32 Limit Switch No.
33 Hardware Set Set.
34
35 Motor Base Plate (50mm S.P) No.
36 Spring Isolators - Fan Side Mounting . No.
37 Spring Isolators - Near to Motor Set.
38 Spring Isolators - Away From Motor No.
39 “BLUE STAR“ Logo (FIXED ON DOOR PANEL) No.
40 Door Switch Bracket No.
41 PTT Joint (25mm Standard)(FIXED WITH EXTRUSION) No.
42 Stickers Set.
43 Rubber Bush / Washer For Cable Entry Set.
44 Rubber Bush / Washer For Coil Header Set.
Assembly Procedure of Double Skin
Horizontal Floor Mounted AHU
The Handling units models DHW - 035C to DHW - 500C are dispatched in SKD condition with Top and Bottom panels assembled. The models DHW - 520C to DHW - 600 C are dispatched in CKD Condition.
A sample packing List for AHUs despatched in SKD and CKD Conditions are shown below:
Packing List 25mm STANDARD
(Screwless Construction)
AHU Model : DHW - 070
AHU Tag No : 3750 CFM
Fan Model : FDA 355 CM
Air Flow : 3750 CFM
Static Pressure : 50 mm
RPM : 1038
Discharge Location : Up blast (CCW 360)
AHU Overall Dimensions : 1370 (W) x 869 (H) x 1555 (L)
Customer Name : 431-162-RVP-AGI-09
ICO No : 431-162-RVP-AGI-09
Batch Quantity : 1
Sr. No. Item Description U.M. CASE No. Size Q / S TOTAL QTY. Puf Panels
1 . Pre Flat Filter
2 . Cooling Coil 6 Row
2 . 1 Panel : Left 460 784 1 1 2 . 2 Panel : Right 460 784 1 1 2 . 3 Panel : Top 460 1285 1 1 3 . Fan Section 3 . 1 Panel : Top 460 1285 1 1 3 . 2 Panel : Top 460 1285 1 1 3 . 3 Panel : Bottom 460 1285 1 1 3 . 4 Panel : Bottom 460 1285 1 1 3 . 5 Panel : Back 620 784 1 1 3 . 6 Panel : Back 620 784 1 1
3 . 7 Panel : Access Door Right 460 784 1 1
3 . 8 Panel : Right 460 784 1 1
3 . 9 Panel : Left 460 784 1 1
3 . 10 Panel : Left 460 784 1 1
Total No. of Panels: 13 13
Aluminium Extrusions
Aluminium Extrusion ‘A’ Type - Height 756 4 4
Aluminium Extrusion ‘A’ Type - Width 1257 4 4
Aluminium Extrusion ‘A’ Type - Length 1442 4 4
Aluminium Extrusion ‘B’ Type 756.4 5 5
Aluminium Extrusion ‘B’ Type 1257.4 3 3
Aluminium Extrusion ‘B’ Type 624.4 1 1
Aluminium Wedges - RIGHT 463 4 4
Aluminium Wedges - RIGHT 767 4 4
Aluminium Wedges - BOTTOM 463 4 4
Aluminium Wedges - BOTTOM 1268 4 4
Aluminium Wedges - BACK 623 4 4
Aluminium Wedges - BACK 767 4 4
Aluminium Wedges - For Frontal Flat Filter Frame(Height) 767 2 2 Aluminium Wedges - For Frontal Flat Filter Frame(Width) 1288 2 2
Aluminum Extrusion BAS-40C-Type ‘Fan side’ 820 2 2
Aluminum Extrusion BAS-40C-Type ‘Motor side’ 635 2 2
Sections
1 Pre Flat Filter
Prefilter: Box Type 48mm, Al Frame EU-3
(90% down to 10 micron) Nos 610 (W) X 610 (H) 2 2
Frontal Flat Filter Frame Set 1285(W) x 784(H) 1 1
2 Cooling Coil 6 Row Section
Cooling Coil Nos YDW-12-A-6-H-C-22-L-40-L 1 1
Cooling Coil Frame Nos 1299(W) x 798(H) 1 1
Insulated Bottom Drain Pan (0.8 mm S.S-304) New Design Nos 1240(W) x 415(L) 1 1
Drain Pan Deflector Plate Nos 1235 1 1
Coil Support for Drain pan Nos 1302 2 2
Rubber Bush / Washer For Coil Header Nos 2 2
3 Fan Section
Fan Nos FDA 355CM 1 1
Motor Nos 3HP, 4Pole 1 1
S.A. DAMPER ,GI(Standard) Nos 452(W) x 452(H) 1 1
Blower Pulley Nos 140mm PCD 30mm ID 1 1
Motor Pulley Nos 100mm PCD 28mm ID 1 1
Belt (PACKED IN HARDWARE BOX) Nos 1060 SPA (1) 1 1
Antivibrant flexible canvass connection Nos 452(W)X452(L) 1 1
Motor Base Plate Nos 3HP 1 1
T-Bolt Nos M10 X 20 12 12
Anti Vibration Isolater - As Shown in Fig. Point 1 Nos RM 19. 100. B 1 1 Anti Vibration Isolater - As Shown in Fig. Point 2 Nos RM 19. 100. R 1 1 Anti Vibration Isolater - As Shown in Fig. Point 3 Nos RM 19. 100. R 1 1 Anti Vibration Isolater - As Shown in Fig. Point 4 Nos RM 19. 100. B 1 1
Marine Light Nos 1 1
Limit Switch Nos 1 1
Polycarbonated Window Nos 1 1
Spool for Vertical Discharge Nos 452(W) x 452(L) x 29(H) 1 1
Door Switch Bracket Nos 1 1
Rubber Bush / Washer For Cable Entry Nos 1 1
Handle For Access Door Nos 2 2
Hinges Nos 2 2
BLUE STAR Logo .(FIXED ON DOOR PANEL) Sets 1 1
Spring Isolater Channel Set 1301 (L) x 85 (W) 2 2
S.A. Flange Nos 452 (W) x 452 (H) x 75 1 1
Channels
Channel, Base. (Width) Nos 1244 2 2
Channel, Base. (Length) Nos 1429 2 2
Channel, Base. (Centre) Nos 1344 1 1
Hardwares
Plastic Corner (for 25mm) Nos 8 8
Assembly the AHU
Base Channel Assembly
1. Assemble GI base channel and corner piece with M6x25 mm long bolt and nut with one plain and one spring washer on each side.
2. Overall dimensions of the base channel frame should be 30 mm less in length and width than the length and width of the AHU / AHU Module.
• Diagonally, the base frame should not be out by more than 1 mm. • All the base corners must be fitted from the inside.
Top Panel Assembly
1. Refer panel arrangement drawing. Assemble ‘A’ type extrusion with glass filled nylon corners to form a top frame required for fixing top panel - Drill the hole of Ø4.2mm & Rivet it with 7/16"x1/2" long rivet.
2. Place the ‘B’ type extrusion on the specified distance mentioned in the panel arrangement Drawing.
3. Place the panel as shown in the drawing and maintain equal gap of 2 – 3mm between frame and panel all around.
4. Insert the taper lock wedge in to the groove of ‘A’ type and ‘B’ type extrusion to lock the panel with extrusion. 5. Rivet the ‘B’ type extrusion on ‘A’ type extrusion by using 3/16" Ø x 1/2" long rivet from inside.
6. If the fan orientation in the AHU is upblast, then fix the canvas connection flange on the cut out of the panel. Reverse the top panel and fix the canvas connection from inside on connection flange.
• Taper lock wedge should be inserted inside the groove of the extrusion until
Bottom Panels Assembly
1. Refer panel arrangement drawing .Assemble ‘A’ type extrusion with glass filled nylon corners to form a bottom frame required for fixing bottom panel .
2. Place the ‘B’ type extrusion on the specified distance mentioned in the panel arrangement Drawing.
3. Place the panel as shown in the drawing and maintain equal gap of 2 – 3 mm between frame and panel all around.
4. Insert the taper lock wedge in to the groove of ‘A’ type and ‘B’ type extrusion to lock the panel with extrusion. Empty space left is for drain pan.
5. Rivet ‘B’ type extrusion on ‘A’ type extrusion by using 3/16"Ø x 1/2" long rivets.
• Taper lock wedge should be inserted inside the groove of the extrusion until
Base Channel & Bottom Frame Assembly
1. Position the base channel frame on the bottom frame. Maintain equal distance from all sides.
2. After positioning the frame, fix it with self drilling and tapping screws of size 4.2 mm Ø x 25 mm long. 3. Use battery operated screw driver / power screw driver with Philips head for fixing self drilling and tapping
screws.
4. Turn the assembly upside down.
• Normally bottom panel frame is 25mm more in size from all the side than
Drain Pan Assembly
1. Position the drain pan in the space left by panels in the bottom frame. Drain nipple should be on the header side.
2. Place the drain pan in position and rivet it to the main frame with rivets of size 3/16" Ø x 1/2" long.
3. Place the coil channel on the top of the drain pan and fix it on ‘A’ type extrusion with the help self drilling / tapping screws.
4. Apply some silicon gel at the periphery / edges of drain pan to avoid leakage.
• Ensure that the drain nipple side of the drain pan should be on the side of
Rubber Mount /Spring Isolator Assembly
1. Refer packing list for the type of rubber mount / spring isolator to be used and position it accordingly. Each type of rubber mount or spring isolator is having different load carrying capacity.
2. Fix the rubber mount / spring isolator on the isolator channel .Place ‘C’ type channel used for blower and motor mounting on the top of spring Isolator as shown in the figure.
3. Level the spring Isolator height and tighten the nuts and bolts properly after providing spring and plain washer. Fix the whole assembly to the bottom frame in the fan section.
Note: Rubber mounts are used for smaller model up to CDHW -120.
• Positioning and fixing of rubber mount / spring isolator at the specified
location is very important since the load carrying capacity of the springs are different.
Vertical Extrusions Assembly
1. Refer the packing list .Pick up vertical ‘A’ type extrusion and confirm the dimension of the extrusion.
2. Insert it in the glass filled nylon corner of the bottom frame assembly.You may hammer the extrusion by plastic or rubber hammer / mallet for the proper fitment.
3. Rivet the extrusion with corner from out side. Rivet size is 3/16" Ø x 1/2" long.
Ensure the length of ‘A’ type extrusion before fixing it, otherwise it may create the problem for vertical panel fitment.
Top Frame Assembly
1. Place the top frame on top of the vertical extrusion. Confirm proper support to the top frame to avoid the breakage of corner.
2. Rivet them together as explained earlier. Diagonally, the frame dimensions should not be out by more than 1 - 2 mm.
3. Overall dimension of the frame should be equal to the length, width and height of the AHU.
• Verify the diagonal distance after placing the top panel assembly and then only
Blower and Motor Assembly
1. Put the self adhesive gasket on the flange of canvas connector and fix it on the cut out panel with the help of aluminium rivet of dia 3/16" * 25 mm long .
2. Place the blower on the mounting channel such that the fan opening matches with the cut out of the panel. Put the self adhesive gasket on the periphery of the fan opening .Fix the other end of canvas connector on the fan opening with the help of rivet of size 3/16" * 25 mm .In case of up blast orientation of fan, spool is to be provided in between fan opening and canvas connector.
3. Mount the motor on the motor mounting base plate and fit it with the help of M8 /M10/M12 Bolt with bigger dia of plain washer and spring washer as per the rating of the motor
4. Refer the packing list and mount pulley on fan and motor shaft Align both the pulleys with the help of straight edge .Mount the v-belt , give the proper tension to v-belt with the help of tension gauge .Tight the motor mounting base plate on channel.
5. Fix both the end of spring isolator channel on ‘A’ type extrusion by using rivets of size 3/16" * 25 mm . 6. Level the height of all the springs by using spirit level and tight the lock nut of the spring Isolator.
• Ensure proper tension of V belt by using belt tension gauge.
Coil Frame Assembly
1. Paste self adhesive foam gasket of size 20 x 3 mm on the end flanges of all four blank off of coil frame. 2. Paste self adhesive foam tape on top, bottom, and side plate of coil. Place the coil frame inside the unit and
position along the ‘A’ or ‘B’ type extrusion.
3. If the coil frame is placed on ‘A’ type, then fix one side of coil frame on ‘A’ type and other side on the sides of coil with the help of self drill and tapping screw.
4. Screws for fixing top and bottom blank off should be fixed from air entry side. Ensure that the 175 mm side coil frame blank off is fixed on the header side of the coil.
5. Once the coil is positioned properly, fixed the coil support on the ‘A’ type with the help of self drill& tapping screws of size 4.2 mm Ø x 25 mm long.
Coil Assembly
1. Put the self adhesive foam gasket on the periphery of the coil flanges.
2. Position the coil on top of coil support channel which is fixed on the drain pan.
3. Header should be on 175 mm side of the coil frame. Coil inlet should be towards the blower side in the draw through AHUs.
4. After positioning the coil, fix it with coil frame with the help of 4.2 Ø x 25mm long self drilling and tapping screws.
Side panel assembly
1. Refer the panel arrangement drawing and place the ‘B’ type extrusion at specified distance and fix it with rivet of size 3/16" * 12 mm long from inside of AHU.
2. Place the panel as per drawing and maintain equal gap of 2 – 3mm between extrusion and panel all around. Insert the taper lock wedge inside the groove of ‘A’ and ‘B’ type of extrusion.
3. Mark the position of the coil header on the panel and make the hole on the header panel. Roll on the rubber collar on the coil header on the either side of the panel.
• Do not forget to put the sleeve and rubber collar on the header.
• Taper lock wedge should be inserted in side the groove of the extrusion until
Door assembly
1. Keep 4 -5 mm distance from ‘B’ type extrusion or ‘A’ type extrusion depend on which the hinge is going to be fixed to the edge of access door for the smooth movement of the door.
2. One end of the hinge is fixed on ‘B’type or ‘A’ type extrusion and other end is fixed on the door. 3. Fix the handle in the hole provided on the door.Also fix the view port with gasket.
• Holes to be drilled on ‘A’ type and ‘B’ type extrusion and fit the nut sert in it for
fixing auxiliary and access door. Ensure the Nut sert machine is available at site.
Filter frame
1. Put the self adhesive foam gasket on the periphery of filter frame. Mount the filter frame on A/B’ type extrusion and fix it by self drilling and tapping screw..
2. Mount the filters in the filter grid. Filters will get automatically locked because of the spring action of the supports provided in the filter frame.
Recommended Tools
Tools required in the Assembly of Screwless AHU
• Hand Drill Machine – (Reverse/Forward) 1 No. • Rivet Machine with Jig – (Manual) 1 No. • Nut Sert Machine – (Manual)
• Spanner 10mm – One side Fix & One Side ring. 2 Nos. • Spanner 13mm – One side Fix & One Side ring. 2 Nos. • Spanner 16/17mm Fix 2 Nos.
• Spanner 19mm – One side Fix & One Side ring. 2 Nos. • Spanner 24/25 mm Fix 2 Nos.
• Adjustable Spanner – 1 No. (Maximum Opening 40mm)
• Ratchet Spanner set with socket – 10mm, 13mm, 15mm, 17mm, 19mm, and 24mm. • Allen key set – 1 No. of Inch and 1 No. of mm.
• Screwdriver – (Flat type – 4 Inch and 8 Inch. Length) • Screwdriver – (Star type – 6 Inch. Length)
• Tester – 1 No. • Knife – 1 No. (Small) • Pliers – 1 No.
• Hacksaw (frame with Blade) • Measuring tape – 5m • Silicon RTV Sealant – 1 No. • Plastic Hammer – 1.5 Inch. - 1 No. • Rubber Mallet – 4 Inch – 1No. • Metal Hammer – 250 g – 1 No. • Spirit level – 1 No.
• Chisel – 3 Nos.
• Screw Bit for 4.2mm Dia, 25mm length Screw – 5 No.
• Screw bit Holder – 150mm, 75 mm For 4.2mm Dia, 25mm length Screw • M6 Bolt Socket of Drill Machine – 1No.
• Hole Saw cutter and Arbor – 25mm, 40mm, 60mm, 75mm, 100mm – 1No Each. • Drill bit – 5mm – 10 Nos.
• Drill Bit – 6 mm – 2 Nos. • Drill Bit – 10 mm – 2 Nos. • Drill bit – 12 mm – 2 Nos. • C Clamp – 6" – 4 Nos.
• Connect the power supply in accordance with local regulations. Earth all equipment at each section. • All wiring must confirm to IS and IE rules and possible local codes.
• The power characteristics, voltage, phase and frequency are stamped on the name plate of the motor. • Whenever possible, electrical conduit/cable should be run to the unit from the bottom of the side panel/skid. • If junction box is provided, electrical cable connection made to the junction boxes on units must be made on the bottom of the box. Installation must comply with code requirements. The installation should be made watertight.
All exposed electricals MUST be checked for tight fastening prior to actual startup. A poor connection can cause overheating and component failure through inadequate current handling capacity.
• A motor connection diagram is affixed on the inside of the motor terminal box cover. Be sure that extra cable length is made available at the motor to permit fan belt adjustment.
• All fan motors are three phase; totally enclosed fan cooled (TEFC) types with squirrel cage rotors. • The fan motors for Ceiling Suspended direct driven types are with single phase.
• Standard motors have radial flow fan allowing fully reversible rotation. The motors are dynamically balanced. Bearings are greased for life with considerable grease reserve.
• Terminate the cable for DOL or Star/Delta as the case may be.
• Check the cable size with respect to motor rating from the approved electrical single line drawing. • Complete both the cable termination and required earthing.
• The AHU starter panel should be close to the AHU. Otherwise provide an isolator switch (disconnect) or on/ off push button station near the AHU.
• The marine light inside will need a single phase 230V, 50 Hz AC supply. Provide an MCB in the AHU panel. • The limit switch (for fan access door) should be wired in the control panel of the AHU starter.
Coil Hand Selection
Coil hand connections (LHS or RHS) should depend on space availability for maintanance. Check the exact inlet and outlet connection of the pipes to the coils. Water enters from the inlet nozzle at the bottom and exits at the top. The water inlet should be at the air-leaving side.
General
• Consult the job specifications and approved drawings for specific piping requirements, coil connection sizes and location. The unit must be levelled to ensure proper venting and draining of coils. The piping arrangement must be for a balanced flow in multiple coil installations.
• The coil will meet performance ratings only if the air velocity is uniform over the face of the coil. High air velocity spots on the coil may cause the carry-over of moisture from the coil. Low air velocity areas of the coil will not deliver published rating. The duct connection must be designed to provide for uniform flow of air across the face of the coil. In case of ducted return air, the entering duct must have a smooth transition from any high velocity effects.
• The heating coil will normally be for reheating. It must be located after the cooling coil in the direction of the air flow.
• Support all connecting piping independent of the coils. Provide swing joints or, preferably flexible fittings in all piping connections, particularly adjacent to heating coils, to absorb expansion and contraction strains. Rigid piping connection can cause coil damage.
