MANUAL

INSTALLATION
OPERATION
MAINTENANCE

Double Skin Modular Air Handling Unit

MODELS DM AHU
DS AHU
AHUR VRV AHU

VER: O-AHU01-4-Aug-23

The design and construction are subject to change without any notice for future improvement.
Table of Contents
1. General ........................................................................................................................ 1
2. Shipment ...................................................................................................................... 1
3. Handling / Rigging ........................................................................................................ 2
4. Storage ........................................................................................................................ 2
5. Assembly and Installation .............................................................................................. 2
6. Commissioning and Operation ...................................................................................... 13
7. Maintenance ............................................................................................................... 16
8. Storage ...................................................................................................................... 21
9. Trouble Shooting......................................................................................................... 21
10. Appendix .................................................................................................................. 23
10.1 Assembly of heat wheel ........................................................................................ 23
10.2 AHU Water Quality ............................................................................................... 23
10.3 AHU Commissioning Check Sheet .......................................................................... 23

1. General determined by International, National or

Local Codes and Regulation.
1.1 Foreword Place of service should be equipped with
the necessary protective equipment, which
This installation, operation and
provide safe maintenance.
maintenance manual is given as a guide to
user of air handling units. The manual
1.4 Unit Decommissioning and
does not limit the users to add other
Disposal
necessary procedures or services for the
continuous successful operation of this At the end of the unit’s useful life, a
equipment. suitably qualified engineer should
decommission it. The parts/materials must
1.2 Warning Notes be disposed of in a correct manner and
comply with the local laws and regulations.
Warning and Important notes are
The unit components shall be disposed of
appearing at appropriate places in this
or recycled as appropriate in the correct
instruction manual. Follow the warning
manner.
notes carefully to ensure correct operation
of the equipment and personal safety. The
2. Shipment
manufacturer assumes no liability for
installation, operation and maintenance The items should be carefully checked
undertaken by unqualified personnel. against the bills of lading to ensure all
crates have been received. All units should
1.3 Occupational, Health and Safety be carefully inspected for damage when
Practices received. Visible or concealed damage
should be reported immediately to the
Connection and start-up of the unit should
carrier and filed damage claims.
be done in conditions, which are in
conformity with Local Codes and
WARNING
Regulations, especially in the field of
operation of electrical devices. DAMAGE OR LOSS OF PARTS IN SHIPMENT OR
The mains voltage must not be turned on AT THE JOB SITE IS NOT THE RESPONSIBILITY
before the unit is connected to the OF MANUFACTURER.
protective system. It is forbidden to make
Air handling units are constructed with
any repair and maintenance activities if
heavy-gauge steel or extruded aluminum
the power supply of the unit is not turned
and are thoroughly inspected before
off. Servicing person, who makes repair or
leaving the factory. Care must be taken
maintenance of the unit must have proper
during installation to prevent damage to
qualifications resulting from the
units. Special care should be taken when
qualification certificate, which is
handling the blower section. All fans are
dynamically balanced before leaving the

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factory. Rough handling can cause Transportation on the building site should
misalignment or sprung shaft. Therefore, be done using forklift truck or a crane
blower fan and shaft should be carefully (See Figure 2). The forks must only be
checked before commissioning to avoid applied under the unit base frame and not
more damage cause by unbalance fan. against the panel. In case when fork of
Screws, bolts, nuts, etc. for assembly of the forklift is too short then suitable
sections are supplied in a bag attached to extensions should be used.
each section. All necessary gaskets are
fixed in the factory.

3. Handling / Rigging
Air handling units can be delivered as
separate section or completely assembled.
To prevent damage to unit cabinet, a
specific lifting method for offloading the
units is recommended as shown in Figure
1. The spreader bars must be in position
Figure 2 - Transportation by forklift truck
to prevent straps or cables from rubbing
the frame panel. Ensure stability and 4. Storage
balance when lifting the units and avoid
twisting or uneven lifting. Uneven lifting For external storage prior to installation,
may lead to accident or fatality which is the units must be protected from dust,
out of factory responsibility. Care should rain, constant sun exposure and rodents.
be taken to prevent coil connections, drain Although covered in shrink-wrapped
pan connection, damper operators and plastic sheeting, this is not intended for
accessory section from damage. long-term storage and should be remove
Do not push hard on the unit it self of on as soon as it is offloaded. Unit therefore
the metal base. Use large wooden beam should be more protected by tarpaulins or
to evenly distribute the force. Dropping similar. Avoid exposed the units for coil
the units will result in permanently connection damages by transient load.
damage of ball bearing, fan shaft or The fan impeller or motor drive must be
loosen coil from the mounting. rotated once every month. Should the
units be stored for a period of exceeding 6
months, then it is recommended that the
drive belts be removed and store
separately.

IMPORTANT
IF LOOSE SECTIONS ARE LEFT UNATTENDED
FOR ANY PERIOD OF TIME BEFORE
ASSEMBLING, THEY NEED TO BE STRAPPED TO
A FIXED LOCATION TO PREVENT THEM FROM
FALLING OVER.
AHU with metal base

INSTALLATION AND MAINTENANCE ARE TO BE

PERFORMED ONLY BY QUALIFIED AND
EXPERIENCED PERSONNEL WHO ARE
FAMILIAR WITH NATIONAL AND LOCAL CODES
AND REGULATION.

5. Assembly and Installation

5.1 General
The system design and installation should
follow accepted industrial practice, such as
AHU with wooden base
described in the ASHRAE Handbook.
Figure 1 - Lifting method when offloading units

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These units are not designed to be
weatherproof (unless equipped with
canopy) and therefore should not be
installed outdoors. Flexible connections
should be used on the outlet and inlet
duct connections for all units. A minimal
amount of air leakage is normal on the
Figure 4 – Air handling unit Plinth Foundation
cabinet and it will not affect unit
performance. The air handling units are 5.3 Section Joint
not design to be suspended from the top
of the unit. Therefore, when the unit is Units that shipped in sections must be
ceiling hung, make sure unit is supported carefully assembled to desired unit
with a base rail of channel. arrangement. The air handling units are
design to use section joint brackets to
5.1.1 Sealant combine two sections. Section joints for
cabinet and base frame are shown in
During installation, due care and diligence
Figure 5 and Figure 6. (provided when
should be exercised to ensure that any
cabinets are joined by intermediate-post
possible gaps or joints are sealed up with
to intermediate-post arrangement)
sealant. Cabinet section joints, ducting
joints and any holes in the AHU for pipes,
cables or wires should be properly sealed
to minimize leakages.

5.2 Foundation
Figure 5 – Cabinet Section Joint
Adequate space should be left around the
unit for coils & drainage piping, filter
replacement, and maintenance. (See
Figure 3). If site access space for coil is
not follow recommendation, AHU need to
dismantle for coil replacement. The unit is
installed at a height that allows the Figure 6 – Base Frame Section Joint
installation of condensate drain trap.
The section joints are pre-installed on
cabinets and base frames as shown in
Figure 7 (For AHU combination of 2
sections and above). The joint for side will
located outside of AHU, joint for top
bottom will be located inside of AHU.

Figure 3 – Recommended minimum service

clearances

To minimize noise transmission, insulation

material (rubber pad) may be placed
between the unit base and the foundation
(See Figure 4) Figure 7 – Pre-installed section joints

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To join two sections, install and level the connected, then only followed by internal
first section in position, then push the section joints. Make sure all joint brackets
second section close to the first section provided are tighten with bolt and nut as
after the alignment is correct as shown in shown in Figure 10. All the bolts and nuts
Figure 8. for the joining are provided and packed
with the unit.

Figure 10 – Tighten the cabinet section joint

WARNING
CABINET SECTION JOINTS ARE NOT INTENDED
FOR LIFTING PURPOSE AND PULLING CABINET
FROM A DISTANCE TO JOIN SECTION
TOGETHER.

When the cabinets are penta-post to

penta-post arrangement or joining two
sections with different cabinet width, then
below type of section joints will be
provided. (See Figure 11)

Intermediate to intermediate post joining

Figure 8 – Combine cabinets

Base frame section joints need to join with

bolts and nuts as shown in Figure 9. Pentapost to pentapost joining

Figure 9 – Tighten the base frame section joint

After base frame being joined, further

tighten the external cabinet section joint.
After the external section joints being

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 Figure 13 – Spring Isolator Adjustment

5.4.2 Restrained Vibration Isolator

Figure 11 – Section Joint for pentapost to pentapost
or different width cabinets The following is applied for plenum or
Lastly, silicone sealant needs to apply to other fan which is using restrained spring
in-between section to seal the gap. For isolator. (See Figure 14). 20mm U-shaped
Hygienic and clean AHU, please ensure plates are inserted between top plate and
that any sealant used do not pose a base plate when shipped out from factory.
microbiological risk as according to the (See Figure 15).
VDI 6022 standard. The VDI 6022
compliant sealant provided along with the
unit should be used for section joint
sealing, otherwise an equivalent sealant
should be used.

5.4 Vibration Isolator

Air handling unit fans are supplied with
internal vibration isolators.

5.4.1 Spring Vibration Isolator

Figure 14 – Restrained Spring Isolator
For model with spring isolators, temporary
transport brackets are fitted to prevent
damage during shipment. All transport
brackets must be removed after
installation and before commissioning.
(See Figure 12)
After removing the transport bracket,
adjust the spring’s height accordingly to
ensure the frame is level before
commissioning. Before turning the
adjustment nut, the locking bolt must be Figure 15 – Removing of U-Shaped Plate
loosened. Turn the adjustment nut bolt
clockwise or anti-clockwise to decrease or 5.5 Arrangement (VRV AHU)
increase the spring’s height. Tighten the
Control box and expansion valve kit are
locking bolt after completing the
installed on the air handling unit. Figure
adjustment. (See Figure 13)
16 and Figure 17 show the proposed
arrangement of component. Item 2, 3, 5,
8 and 10 in Figure 16 and Item 2, 3, 6, 9
in Figure 17 will be supply by factory.
Refer to Installation and Operation manual
of “EKEQMCBAV3 / EKEQFCBA – Option kit
for combination of Daikin condensing units
with air handling units” for further
Figure 12 – Removing of transport bracket instructions.

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Standard Air Series VRV AHU 5.6 Coil Installation/ Pipe Connection

5.6.1 General
The coil will perform as per rating only if
the airflow is uniformly pass-through the
coil surface.

IMPORTANT
HIGH VELOCITY SPOTS ON THE COIL MAY
CAUSE MOISTURE CARRY OVER. THEREFORE,
UNIFORM AIRFLOW ACROSS COIL SURFACE IS
CRUCIAL.
Figure 16 - Standard Air Series VRV AHU Unit
External pipe-work must be adequately
1. Outdoor unit supported to ensure load-free towards coil
2. Control box connections. Swing joints or flexible
3. Air Handling unit fittings are to be provided in all piping
4. Field piping (field supply) connections, particularly those adjacent to
5. Expansion valve kit heating source, to absorb expansion and
6. Outdoor unit power supply contraction strains. Failure to comply will
7. Control box wiring result in damage to the coils & headers.
8. Air handling unit thermistors
9. Power supply and control wiring IMPORTANT
for air handling unit and controller
TO AVOID DAMAGING THE COIL
10. Air thermistor control for AHU
CONNECTIONS AT COIL HEADER, IT IS
11. Remote controller
ESSENTIAL TO HOLD THE CONNECTOR / PIPE
WITH TOOLS WHILST APPLYING COUNTER
Outdoor Air Series VRV AHU
FORCE TO TIGHTEN THE JOINT. (See Figure 18)

Figure 18 – Coil header connection method

Figure 17- Outdoor Air Series VRV AHU Unit

1. Outdoor unit
2. Control box
3. Air Handling unit
4. Microtech III
5. Field piping (field supply)
6. Expansion valve kit
7. Outdoor unit power supply
8. Control box wiring
9. Air handling unit thermistors
10. Control wiring for control box and
Microtech III Figure 19– Bulb orientation and position
11. Power supply and control wiring
for air handling unit and controller Figure 19 shows the correct mounting
12. Remote controller method and the position of TXV sensing
bulb according to the piping size.

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 the suction piping must be installed in
IMPORTANT such a way that refrigerant from one coil
WRAP WET CLOTH AROUND PIPE BEFORE suction header cannot reach another coil
PERFORM BRAZING TO PREVENT OVERHEAT suction header. The bulb for the control
PIPE AND DAMAGE COMPONENT AT PIPING. valve must be attached to the header or
(Figure 20) the coil or section of coil fed by valve and
not to a common header. When two or
more coils are connected to a common
suction line, never place the bulb on the
common line.
Thermostatic expansion valve is to be
equipped with external equalizer tubes
Figure 20 – wrap wet cloth before brazing
that are field connected to the suction line.
The valve should be in accordance to the
AFTER PIPE-WORK DONE, SITE INSTALLER manufacturer recommendations, allowing
MUST WRAP THE PIPE CONNECTION WITH approximately 35-psi pressure drop
INSULATION AND SEAL THE HOLES BETWEEN through the coil and distributor at full load.
PIPE CONNECTIONS AND PANEL. Do not oversize the valve, proper
expansion valve operation is necessary in
5.6.2 Water Coil
order to realize the rated coil capacity.
Water supply, water return, drains and
vents connections are extending through
the end panel of the coil section. All IMPORTANT
connections are labeled on the end panel. CAREFULLY READ THROUGH
For control equipment, follow MANUFACTURING INSTRUCTION FOR APPLING
recommendations from the manufacturer ANTI-FREEZE SOLUTION. SOME PRODUCTS
regarding the types, sizing and installation WILL HAVE DIFFERENT FREEZING POINT IN ITS
of equipment. Hot water coils are not NATURAL STATE WHEN MIXED WITH WATER.
recommended to be used with entering air COIL FREEZE-UP IS NOT THE RESPONSIBILITY
below 40oF (4.4oC). Refer appendix 9.2 for OF MANUFACTURER
water quality.
It is not recommended to operate DX coil
5.6.3 Winterizing Water Coils for air-conditioning purpose at below
freezing suction temperature, 0oC which
Coil freeze-up may occur due to air
will result frost build-up at fins surface. If
stratification, failure of outdoor air
the full load operating point for the coil is
dampers and/or preheat controls. Routine
selected at a “safe” temperature, a system
draining of water coils for winter shutdown
analysis is required to check for the lowest
cannot guarantee zero freeze-up incidents,
probable suction temperature at light load
which may result in coil damage. It is
condition.
recommended to completely drain the coil
and treated with anti-freeze solution. 5.6.5 Piping Diagram (VRV AHU)
Fill each coil independently with an anti-
freeze solution by using a small circulating For piping diagram of VRV AHU model,
pump follow by complete draining. Check please refer to the VRV ED or refer to
the freezing point of anti-freeze before manufacturer for advices.
proceed in each coil. Diluted effect
normally occurred due to a small amount 5.6.6 Steam Coil
of water always remaining in each coil. All field brazing and welding should be
Therefore, ensure sufficient amount of performed using high quality materials and
anti-freeze solution be remained in coil to an inert gas purge, such as nitrogen, to
prevent freeze-up. reduce oxidation of the internal surface of
the coil. All piping must be fully supported
5.6.4 Direct Expansion Coils
at locations other than the coil. The piping
For each coil, individual expansion devices should be flexible enough to provide no
must be provided for header suction forces on the coils due to thermal
connection. If the air flow through two or expansion. Do not support piping from coil
more coils in parallel or stacked coil bank,

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or headers. Vent each coil at its highest CAN CAUSE SERIOUS BODY INJURY THAT MAY
location to ensure the exit of gases and to RESULT IN DEAD.
promote proper drainage. Piping should be
the same size as the inlet and outlet 5.6.7 Drain Pan Trap
connections. For threaded pipe Drain pipes and traps must be at least
connections, use only good quality fittings same diameter as the drain pan
with tapered threads. Use of liquid Teflon connection. Drain pan must be level to
pipe joint compound is recommended. permit condensation from coil drain freely
Threaded piping hook-ups should always for the recommended depth and distance
be made using two wrenches. Manual of drain trap installation. (See Figure 22)
service valves should be installed to isolate Drain pan are not designed to be walked
the coil for servicing. on.
The flange or union is located to facilitate
coil removal. Flash trap may be used if
pressure differential between steam and
condensate return exceeds 5 psi. Dirt leg
may be replaced with a strainer. If so, tee
in drop can be replaced by a reducing
elbow. The petcock is not necessary with
a bucket trap or any trap which has
provision for passing air. The great
majority of high or medium pressure
returns end in hot wells or deaerators
which vent air. All coils in a system should
be piped separately. It is not
recommended to put multiple coils on a
common trap. Vacuum breakers and air
vents should be piped to a drain or other
suitable location where discharged steam Figure 22– Drain Trap Arrangement
cannot lead to personal injury.
Steam piping and related components
must be installed in accordance with all 5.7 Electrical Installation
national and local codes, and in
accordance with the local authorities Electrical wiring design and installation on
having jurisdiction. the unit are based on factory standard
practice. All installation and management
activities must be carried out by qualified
personnel, and shall ensure compliant with
relevant local laws and regulations
Refer to the specific wiring diagram and
electrical component manual are attached
with the product before electrical
installation. Site contractor shall do
termination at site for wiring connection
between components that located at
different AHU sections and delivered
separately.

IMPORTANT
Figure 21 – Standard steam pipe layout for horizontal
coil arrangement MAKE SURE ALL THE ELECTRIC POWER
DISCONNECT AND SECURE FROM SWITCH ON
BEFORE DOING WIRING CONNECTION
IMPORTANT
ENSURE THAT THE SYSTEM IS OFF OR THE 5.7.1 Motor Connection
COMPONENTS ARE ISOLATED BEFORE BEGIN
The electric supply to the motor must
THE WORK. EVEN AT LOW PRESSURE, STEAM
correspond to the rated voltage stated in
motor nameplate and be in conformance

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with the National and Local Electric Code
and Regulations. Motor supplied able to
operate within 10% tolerance from the
nameplate voltage. Motor connection
details are contained in the cover of the
motor terminal box. (See Figure 23). The
fan section metal frame must be grounded.
Suitable electrical protection isolator Figure 24 – Motor Cabling
should be installed to protect the motor
and other electrical equipment.
Flexible conduit must be used when wiring 5.8 Drive Belt & Sheave
up fan motors to allow the fan motor to
move freely on its anti-vibration mounts. Improper sheave alignment and belt
Cables passing through panels must be tension can cause excessive vibration,
made with gland or grommet. premature failure of belts and bearings.
Recommendation from factory, motor of See Figure 25 for correct motor sheave
4kW and below using Direct On Line (DOL) and fan sheave alignment.
while motor of 5.5kW and above using Tensioning of the drive belt is achieved by
Star-Delta (SD). moving the motor in relation to the fan
For inverter control, refer to the VFD (See Figure 26). When inserting new belts,
manual for wire size and requirements. do not force belts over grooves, Loosen
the adjusting screw at motor base until
belt can slide smoothly over the grooves.
When all belts are in position, proceed to
adjust belt tension using the adjusting
screw and nuts on the motor base.
Use recognized belt tension gauge to
check the belt tension by apply a force
large enough at the center of the belt to
deflect the belt by 16mm per meter (See
Figure 27). The deflection force for any
belt should be within the minimum and
maximum force shown in table 1. Readjust
the tension to maximum value when it
drops to min. value. The deflection force
of factory setting is based on “Initial
Fitting”, re-tensioning as “Retension” after
the unit has run for 24 hours.

WARNING
OVER TENSION TOWARD DRIVE BELT WILL
CAUSE PREMATURE FAILURE OF BELT AND
BEARING DAMAGE.

Figure 23– 3 phases motor connection diagram

5.7.2 Motor Cabling

Motor wiring must go downward from
motor terminal box to prevent
condensation water flowing into motor
and lead to a failure. (See Figure 24)

Figure 25 – Alignment of belt pulley

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 Figure 26 – Belt tensioning Figure 27 – Belt deflection distance

Table 1 - Belt Tensioning Force

Deflection Force (N)
Belt Section Pulley Diameter Initial Fitting Retension
Min Max Min Max
SPZ <70 12 17 12 16
71-90 15 22 15 19
91-125 19 27 19 24
126-200 23 34 23 30
SPA <100 20 29 20 25
101-140 27 39 27 34
141-200 32 47 32 40
201-315 36 55 36 47
SPB <160 36 54 36 46
161-224 46 67 46 58
225-355 53 79 53 69
356-400 55 82 55 71
Refer to factory specifications for tension values that are not included
Refer to the diameter of smaller pulley

Table 2 - Adjusted Pitch Diameter

VPT120A1 VPT139A1 / VPT156A1 / VPT177A1
Model VPT100Z1 VPT178B2
/ A2 A2 A2 / A2
Max. Pitch Ø (mm) 96 114.4 133.4 150.4 171.4 171
Min. Pitch Ø (mm) 82.9 96 115 132 152.5 146.5
Adjusting Factor(mm) 1.089 1.227 1.089 1.089 1.452 1.635
Adjusted Adjusted Adjusted Ø Adjusted Ø Adjusted Adjusted
No. of Turning
Ø (mm) Ø (mm) (mm) (mm) Ø (mm) Ø (mm)
0.25 94.91 113.17 132.31 149.31 169.95 169.37
0.5 93.82 111.95 131.22 148.22 168.50 167.73
0.75 92.73 110.72 130.13 147.13 167.04 166.10
1 91.64 109.49 129.04 146.04 165.59 164.46
1.25 90.56 108.27 127.96 144.96 164.14 162.83
1.5 89.47 107.04 126.87 143.87 162.69 161.19
1.75 88.38 105.81 125.78 142.78 161.24 159.56
2 87.29 104.58 124.69 141.69 159.78 157.92
2.25 86.20 103.36 123.60 140.60 158.33 156.29
2.5 85.11 102.13 122.51 139.51 156.88 154.65
2.75 84.02 100.90 121.42 138.42 155.43 153.02
3 82.93 99.68 120.33 137.33 153.98 151.38
3.25 - 98.45 119.24 136.24 152.52 149.75
3.5 - 97.22 118.15 135.15 - 148.11
3.75 - - 117.07 134.07 - -
4 - - 115.98 132.98 - -

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5.9 Accessory Items and clean AHU units, please ensure that
any sealant used do not pose a
5.9.1 Filter microbiological risk as according to the
Air handling units can be supplied with flat VDI 6022 standard)
filters and/or bag filters. There are 2 types Refer to assembly of heat wheel baffle
of filter frame, sliding frame or universal plates at Appendix 9.1 when the heat
clip. Insert the filter into the frame by wheel section not able to ship in complete
following airflow arrow indicated. build up.

5.9.2 Mixing Box 5.9.5 Heat Pipe

Fresh air and return air dampers can be After installation of Heat Pipe with refers
linked together and drives by the same to manufacturer recommendations, site
actuator if both are same size. Care must installer to install heat pipe baffle plates at
be taken to ensure dampers are in open site, this is to avoid air bypass heat
position while the fan is running whether pipe/main cooling coil from top and side.
they are integral with central plant control (If applicable)
or associated ductwork under negative
pressure condition. 5.9.6 Electric Heater
Power supply to electric heater and
5.9.3 Variable Pitch Pulley electric connection is in accordance with
Modifications of the pulley diameter must wiring diagram in terminal box of electric
be done when stationery by moving the heater.
adjustable flange. Each complete rotation The rated voltage of electric heater is
of one of the two disks results in a 240V, single phase.
variation of the pulley diameter. (See
Table 2 & Figure 28) When the required
diameter is obtained, adjustable flange is IMPORTANT
locked by tighten the four clamp screws. IT IS ADVICED TO INTERLOCK ELECTRICAL
To get the same diameter in the two HEATER WITH BLOWER TO ENSURE HEATER IS
grooves of pulleys, screw the two mobile NOT ENERGIZED WHEN THERE IS NO AIR
flanges on the central flange. Then FLOW.
unscrew the two mobile flanges by the
same number of turnings to get the 5.10. Ductwork
required diameter.
Note that the belt centre line shifts when Connections to unit cabinet are made by
diameter changes. Driven pulley may need site drilling into the frame on the unit inlet
realignment. or fan discharge collar. This should be
load-free toward cabinet collar when initial
positioned.
Compliance with the Codes of Practice in
duct assembly and acoustic layout are
necessary to ensure the best possible
performance of the unit whilst avoiding
excessive pressure loss in the duct system
and minimize undue air stream noise. Duct
connections to and from units should allow
straight, smooth airflow. Sharp turns in
the fan discharge should be avoided,
particularly turns opposed to wheel
Figure 28 – Variable Pitch Pulley rotation. Turning vanes should be used.
Discharge plenums or any abrupt change
in duct should be avoided.
5.9.4 Heat Wheel
Follow Heat Wheel manufacturer
recommendations for proper installation
procedure. Apply silicone to air leak spots
at baffle plates. (If applicable. For hygienic

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 Figure 31 – All edge to be seal by site if the flange
was sent separately / unit is CKD

Figure 29 – Discharge duct layout

For outdoor unit, the return duct should
Notes: be large enough to cover the exposed
1. Elbows should not be closer than area of AHU to prevent rain water from
2-1/2 times the Duct Equivalent seeping into the unit.
Diameter. (Refer to Formula 1)
2. Dampers should be placed at least In case of hygienic and clean AHU, the
fan diameters downstream of the ducts should be made from closed pore
fan discharge. material without grooves. A flexible
connection with folds is not allowed.

Formula 1 - Duct Equivalent Diameter Figure 32 – Front view of Return duct to be large
enough to cover exposed area
All duct joints, edges, opening area of top
roof (example: top discharge, top damper
and top roof with opening), must have
skirting and fully sealed to avoid leakage
and rain water seepage into the unit (if
unit is placed outdoor).
Figure 33 – Side view of Return duct to be large
enough to cover exposed area

IMPORTANT
Top roof are not intended for people to
step on.

5.11 Assembly of Complete Knock

Down Unit (CKD)
Due to container size constrain, some air
handling units are packed in unassembled
condition - CKD method. All parts required
are packed in section by section. It is
recommended to open one section at a
time to avoid confusion when assembly.
For CKD, additional drawing will be
Figure 30 – Site to seal gap between roof and duct
provided for assembly at site.

5.12 Component Removal and

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 Replacement The complete air handling unit and all
accessory components should be
5.12.1 Panel Removal thoroughly cleaned and all dust & debris
To remove side or top panel, simply completely removed.
unscrew the fasteners located along the Make sure that all transport brackets and
aluminum clip on the frame of Air packing have been removed.
Handling unit cabinet. Once the aluminum Ensure all screws, bolts and nuts on AHU
clips are removed, lift the panel off. are secured tightly (not loose during AHU
transportation or handling).
Ensure all panel and belt drive settings are
5.12.2 Fan / Motor secured due to change during shipment or
The fan shaft, motor and drive installation.
components can be removed and replace In case additional equipment is installed at
through the access door opening or side site, ensure air leaking spots are being
panel removal if additional access required. seal with additional baffle plates or seal
For fan replacement, the entire fan with silicone to prevent air bypassing. For
assembly can be pulled out from side or Hygienic and clean AHU, please ensure
front (for top discharge) of the cabinet. that any sealant used do not pose a
Dismantle the intermediate fan supports microbiological risk as according to the
and canvas follow by loosening bolts & VDI 6022 standard.
nuts at motor and drive belts. Then The lamination films stick on the PU panel
remove the belts and nuts from Fan act as protection film for PU panel. It is
mounting frame. Take out the fan and normal that the films torn or dirt from the
replace with new fan with care. Re- protection purpose. Peel off the lamination
connect the shaft and bearings and fan film when the unit is in position.
assembly.

WARNING
5.12.3 Coil
ISOLATE THE ELECTRICAL & MECHANICAL
The coil can be pulled out from side or top ENERGY SOURCE AND PADLOCK THE SWITCH
of cabinet. The coil is fastened with bolts BEFORE SERVICING THE FANS AND MOTORS.
and nuts on the coil support bracket at the
end plate and baffle plate. Before removal
of coil, ensure the piping connections at 6.1.2 Fan / Motor
header are disconnected. In case where
two coils are stacking, remove the drip Make sure the fan impeller can rotate
pan and join brackets which holding the freely by hand. Check the tension and
two coils together. alignment of the belt drive.
For DX coils, it is advisable that the Check motor connections and make sure
refrigerant is to be pumped into the correct voltage is supplied. If standby
condenser. If this is not possible, motor is available, make sure only one
refrigerant shall be purged out. motor to power source.
Seal end of fan motor conduit (if
applicable) and the motor terminal box
WARNING with silicon sealant. For Hygienic and clean
DO NOT HEAT ANY PART ON DX COIL IF AHU, please ensure that any sealant used
REFRIGERANT STILL IN THE SYSTEM. HEATING do not pose a microbiological risk as
UP WILL CAUSE DANGER OF HIGH PRESSURE according to the VDI 6022 standard.
INSIDE THE COILS.
VFD/Frequency Inverter for TEFC motor
can only vary the frequency within 30 to
6. Commissioning and Operation 60 Hz in order to control the motor
rotation speed. For VFD setup, make sure
6.1 Pre-run Check the VFD settings according to
6.1.1 Preparation recommendations at VFD manual.

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When multiple fan with multiple VFDs, spring isolator should be approximately
fans must set up to always start 10-20mm.
simultaneously and with same speed.
6.1.5 Coils
It is recommended that the fan speed
does not exceed the speed specified in the Check the pipe-work to coil is correctly
technical report. If ramp up fan speed connected and the fins are free from
beyond specification, make sure it does foreign matter or damage.
not cause any issues such as water carry Check that the condensate drain is trap.
over. Ensure good sealing of silicon around the
coil headers and drain pipe.
6.1.3 Fan Array Make sure operating pressure is within
design limits.
Fan array is available for EC plug fan.
Ensure all fans are control to run 6.1.6 Steam Coils
simultaneously and with same speed.
Fans running at unequal speeds can result Proper air distribution is vital to coil
uneven airflow that cause performance, performance. Air velocity anywhere on the
sound, vibration problems that lead to coil should not vary by more than 15%
failure. from the average velocity. Air velocities
In case one of the fan is down, blank off should be maintained between 200 and
plate shall be temporarily installed on the 1500 feet per minute. Operating pressures
nonfunctional fan to prevent air re- must be at or below the maximum
circulation while waiting fan replacement operating pressure for the coil at steam
(See Figure 34). If present of differential temperature. Pressure and temperature
pressure controller, ensure the pressure limitations can be referred to COC of
tube of nonfunctional fan is capped and vendor provide.
amend the setting of controller accordingly.
6.1.7 Damper & Filters
Check all dampers are operating correctly
as per design.
Make sure all filter media are installed in
correct airflow direction.

6.1.8 Panel & Section

Ensure all access panels are in position
and secure. Make sure all necessary
section joints are in place.

6.1.9 Electric Heater

Figure 34 - Fan Array with Blank-off Plate Electric Heater – Before starting-up,
ensure that the air flow through the
heater should not be lower than 2.0 m/s
6.1.4 Vibration Isolator Mount to avoid overheating heater. Optional
items of airflow switch and differential
Ensure the vibration isolator mounts and
pressure switch (50-500Pa setpoint range)
flexible connections allow the fan and
only indicate fan is running. Setting
motor to move freely without constrain.
adjusting is necessary in some situations
For the fan with Restrained Spring Isolator,
for proper operation.
ensure that the Alu Angle plates are
removed from the restrained spring
For Hygienic and clean AHU, it is
isolator before commissioning.
recommended to select and adjust the
electric heater such that the relative
IMPORTANT
humidity in the Air Handling unit is less
The clearance between flanges of “Top than 80% to avoid microbial growth issues.
plate” and “Base plate” for restrained

- 14 -
WARNING IMPORTANT
FOR 380-415V/3PH, STAR CONNECTION FAILURE TO PROVIDE MOTOR OVERLOAD
WITHOUT NEUTRAL (Figure 35), UNBALANCED PROTECTION COULD RESULT IN MOTOR
PHASE VOLTAGE MAY CAUSE DAMAGE ON DAMAGE. CONNECT THE MOTOR TO AN
THE ELECTRIC HEATER. OVERLOAD PROTECTIVE DEVICE THAT IS
RATED IN COMPLIANCE WITH THE APPLICABLE
CODE.

a. Check the rotation of the fan impeller.

If the fan rotates in opposite direction
from desire, reverse any two phase
connection at motor terminal.
b. Check that there is no unusual noise
or vibration. Stop and investigate if
found. (refer to section 8)
Figure 35 - Wiring Diagram without Neutral c. Measure the voltage and drawn
current of the motor. The drawn
current must not exceed the full load
FOR 380-415V/3PH, STAR CONNECTION WITH current mentioned at motor
NEUTRAL (Figure 36), NEUTRAL POINT MUST nameplate.
BE CONNECTED IN ACCORDANCE WITH d. Heat Wheel – Ensure the heat wheel
WIRING DIARGRAM IN ORDER TO CARRY can rotate freely by hand.
CURRENT DUE TO UNBALANCED PHASE e. Heat Pipe – Ensure installations are as
VOLTAGE. per manufacturer recommendation.

IMPORTANT 6.3 After first 48 hours of operation

SAFETY THERMOSTAT IS FOR OVERHEATING
a. Make sure complete isolate the
PROTECTION ONLY, NOT FOR CONTROL
Electrical source.
PURPOSE. DEFAULT SETPOINT IS 60˚C.
b. Re-check and Re-tension the drive
IT MUST BE CONNECTED TO CONTACTOR
belts due to stretch.
(WHETHER SUPPLIED BY FACTORY OR SITE) TO
c. Check and adjust the pulley alignment
CUT-OFF HEATER IN CASE OF OVERHEATING
to ensure the motor fixing is properly
HEATER.
secure.
d. Check all bearing, wheel bolts & nuts
and sheave set screws (or cap screw)
are in secure position.

CAUTION
HIGH AIR TEMPERATURE IN FAN SECTION CAN
CAUSE MOTOR OVERHEAT AND DAMAGE. ON
DRAW-THROUGH AIR HANDLERS, ADJUST THE
DISCHARGE AIR TEMPERATURE OF THE
HEATING SECTION NOT TO EXCEED 1040F
(400C).

Figure 36 - Wiring Diagram with Neutral

6.4 Fan Operating Limits
The fan operating limits shall refer fan
datasheet and individual technical
6.2 Start-up Check specification file of the AHU to determine
Competent, well-trained personnel must the operation of the AHU blower and
be employed in the following operations to motor.
ensure Safety Rules and Regulation being Fan speed maximum operation should be
adhered to at all time. ≤ 90% of max. fan speed. The motor

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running current should not more than
motor nominal current. For Hygienic and Clean AHUs, ensure that
the water in the humidifier is clean
according to standards of the Drinking
6.5 Installation of VRV AHU Control Water Ordinance (TrinkwV) and the
Box (EKEQ) requirements of VDI 3803 Part 1, Table B1.
For installation VRV AHU Control Box,
6.9 View Port Cover Commissioning
please refer to the Installation And
After AHU has been placed on desired
Operation Manual in VRV ED or refer to
location, remove the 2 screws at the
manufacturer for advices.
bottom of view port cover so that view
6.6 MicroTech III Commissioning port cover is able to be swing open or be
removed.
MicroTech III is an option. For
commissioning of MicroTech III, please
refer to the MicroTech III Commissioning
Manual in VRV ED or refer to
manufacturer for advices.

6.7 DMA6 Door Opening

Figure 39 – Screw Location on view port cover

Figure 37 – Universal Handle

7. Maintenance
DMA6 doors with the universal handle
shown in Figure 37 are able to open from 7.1 Fan / Motor
the left or right direction or removable. If Check for soiling, corrosion, damage and
opening door while the fan is running, tendency of excessive vibration.
make sure to open handles on one side Check that all bolts and nuts and flexible
only. For example, either only open all connections are securely fixed.
handles on the left or only open all Check that vibration isolator mounts are
handles on the right side. functioning well.
Inspect for any obstructions or blockages
at air intakes and discharges.
Check fan bearings are secured and no
undue noise by observe/listen using metal
bar as a conductor.
If unit equipped with belt guard, check
that it is fitted correctly and secure.
If there is any undue noise or knocking
from bearing, replace both bearings. Fan
Figure 38 – DMA6 Door Opening Procedure while fan bearing are grease for life, but larger units
running with standard bearing require semi-annual
6.8 Humidifier Commissioning or annual lubrication at bearing greasing
When turning on the humidifier, ensure nipple. Recommended lubricants are
that the moisture eliminator is installed to Standard Din 51823, K3N or ISO XM2.
avoid water carry over during system
commissioning. 7.2 Drive Belt

During system standstills, blow dry the Belts that are split or have frayed edges or
drain pan by turning on the fan but any other sign of damage (rubber shred
keeping the humidifier turned off. on floor) must be replaced in full set.

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 as well as inspection of condensate traps,
IMPORTANT vacuum breakers, air vents, and valves.
DURING MAINTENANCE AND SERVICING, UNIT Boiler water analysis should also be
MUST BE COMPLETELY ISOLATED AND performed on a regular basis. To
PRECAUTIONS TAKEN TO PREVENT ACCIDENT continually deliver full heating capacity,
FROM HAPPENING. both the external and internal heat
transfer surfaces must be maintained as
Check the belt tension and alignment, re- clean and corrosion free as possible. The
tension and re-align if necessary. Refer to finned surface can be maintained by the
Section 5.7 for belt tensioning procedure. use and constant inspection of pre-filters.
New belt drive must be re-tensioned after The filters should be replaced as needed.
the first 48 hours of operation. Should the finned surface become fouled,
For replacement of belts, remove the belt the coil can be cleaned using commercially
guard before starting work. To change the available coil cleaning fluids. Caution
belts, first loosen the adjusting screw and should be exercised in selecting the
move the motor towards the fan to enable cleaning solution as well as the cleaning
old belts to be taken off and put on of equipment. Improper selection can result
new belts. (Matched belts must be used) in damage to the coil and health hazards.
Tension the belts by following instruction Be sure to carefully read and follow the
at Section 5.7. cleaner manufacturer’s recommendations
before using any cleaning fluid. Clean the
7.3 Coil Section coil from the leaving airside so that foreign
Periodic cleaning of coils is required. Dirty material will be washed out of the coil
coils have tendency to increase airside rather than pushed further in. Internal coil
pressure drops and reduce cooling/heating maintenance consists primarily of
efficiency. Dry cleaning is done by using a preventing scale and corrosion. This is
powerful vacuum cleaner on the dust- accomplished through aggressive boiler
accumulated side. If coil is very dirty, coils water treatment, removal of dissolved
need to be removed for wet cleaning by oxygen, and the removal or non-
trained personnel. Ensure coil fins are not condensable gasses such as carbon
damage when performing dry/wet dioxide.
cleaning. In the event that fin edges have
been bent, treat with aid of a coil comb. 7.5 Filter Section
Check that frost protection is working
During system start up, filters are likely to
before starting of each winter season.
become rapidly blocked.
Ensure the frost sensor is correctly
installed and working within desired Disposable filters and bag filters must be
temperature range. replaced each time when pressure drop
For direct expansion coils, do not use hot reaches the indicated dirty condition by
water or steam to clean these coils. During D.M. Manometer. Washable filters must be
normal operation, the fin block must not cleaned periodically.
be ice up. If this occurs, check the
refrigeration system. 7.6 Dampers
Check that drain pan and drain trap are
Check for dirt accumulation, damage and
free from blockage and water
sign of corrosion. Clean with cloth or high
accumulation at pan.
pressure air. Check damper blade turning
7.4 Steam Coil Section
manually or central control for smooth
Scheduled plant maintenance should operation.
include the draining and flushing of the
condensate drip legs and sediment traps

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 Table 3 - Recommended Maintenance intervals (based on 12 hours operating time per day)
Maintenance interval
Component Description Action
Weekly Monthly 3 Monthly 6 Monthly Yearly

Fan / Motor Fan in general Check / Clean ●

Fan bearing Check / Replace / Greasing* ●
Motor in general Check / Clean ●
Motor bearing Check ●
Motor temperature Check / Repair / Replace fan ●
Belt drive tension Check / Re-tension ●
V-Belt condition Check / Replace ●
Corrosion Check / Treat / Repair ●
Bolt & nut secure Check / Tighten ●
Excessive vibration Check / Resolve ●
Flexible connection Check / Tighten ●
Vibration isolator Check / Tighten ●
Intake air not obstruct Check / Clear ●
Coil Section Fin block Check / Clean ●
Frost protection Check / Apply ●
Drain trap clog Check / Clear ●
Corrosion Check / Treat / Repair ●
Leakage Check / Repair ●
Bolts & nuts secure Check / Tighten ●
Filter Resistance (Washable) Check / Clean ●
Resistance (Disposable) Check / Replace ●
Damper Dirt accumulation Check / Clean ●
Sign of damage Check / Repair / Replace ●
Turning torque Check / Repair ●
Electrical Control box & wiring Check / Repair / Replace ●
Control Protection breaker Check / Calibrate ●
Internal lighting Check / Replace ●
Dirt accumulation Check / Clean ●
Electric Heater
Safety cut out Check ●
Refer Manufacturer
Functionality
Recommendation ●
Heat Wheel / Refer Manufacturer
Functionality
Heat Pipe Recommendation ●
Moisture
Dirt accumulation Check / Clean
Eliminator ●
* Depend bearing type and condition

Table 4 - Recommended Maintenance interval for hygienic and clean AHU

Maintenance interval
Component Description Action if required (months)

1 3 6 12 24
Outdoor - air
inlets and Check for any signs of damage,
exhaust-air corrosion or contamination
Clean / Repair ●
outlets
Unit casings Check for contamination, damage and
corrosion on air-side
Clean / Repair ●
Check for condensation Clean ●

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 Check casing for contamination,
damage and corrosion
Clean / Repair ●
Static
Check condition of condensate trays
cooling
and drains
Clean / Repair ●
components
Recirculating
Air Check if there is any contamination,
humidifiers damage, microbial growth and Clean / Repair ●
corrosion

Function-check shutdown controls Readjust ●

Determine the total number of Colony If number of CFUs > 1000 CFU/mℓ:
Semi -
Forming Units (CFUs) in the Clean, rinse and dry the tray;
monthly
recirculating water disinfect; test quality of supply water
Check spray nozzles for deposits Clean / replace nozzles ●
Check circulation pump for
contamination and scaling in the
suction line, check condition and
Clean pump circuit ●
functioning of filters
Function-check conductivity sensor Repair ●
Function-check disinfection system Repair ●
Completely empty and dry humidifier During
system standstills
Check moisture eliminator for If deposits formed, extract and clean
contamination, damage, scaling and unit and then check the region ●
corrosion downstream of droplet eliminator
Non -
recirculating Check if there is any contamination,
Air damage, microbial growth and Clean / Repair ●
humidifiers corrosion

Check for condensate precipitation in

the chamber
Clean / Repair ●
Check steam distribution system for
deposits
Clean ●
Check spray nozzles for deposits Clean / replace nozzles ●
Check drain pan Clean / Repair ●
Determine the total number of Colony If number of CFUs > 1000 CFU/mℓ:
Forming Units (CFUs) in the humidifier Clean, rinse and dry the tray; ●
water disinfect; test quality of supply water
Function-check control valve Repair ●
Check humidity limiter Repair ●
Maintenance interval
(months)
Component Description Action if required
1 3 6 12 24
Air filters Check for contamination, leaks and
odours for filters
Change affected air filters ●
Check differential pressure Replace filter stage ●
Maximum interval until first filter needs
to be changed ●
Maximum interval until second filter
needs to be changed ●
Fan Check for contamination, damage and
corrosion on air-side
Clean / Repair ●
Heat Visual inspection of air to air plate heat
exchangers exchangers for contamination, damage Clean / Repair ●
and corrosion
Visual inspection of rotary heat
exchangers for contamination, Clean / Repair ●
damage, corrosion and tightness
Visual inspection of directly heated
heat exchangers for tightness
Ensure tightness ●

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 Heaters: Check for contamination,
damage, corrosion and tightness
Clean / Repair. Replace if required ●
Coolers: Check tube bundle, moisture
eliminator and condensate tray for
contamination, corrosion, damage and
Clean / Repair ●
tightness
Function-check drain and drain trap Clean / Repair ●

7.7 Electric Heater that the heat wheel media is not damaged.
Finally, for firmly attached dirt in the rotor,
Check for dirt accumulation and clean if
use hot water and a mild detergent to
necessary with a soft brush. Check the
remove the dirt. The mild detergent may
safety control, cables and connections
be removed with high pressure water
operation.
cleaner with the nozzle 300mm from the
heat wheel. For disinfection, please use an
IMPORTANT
isopropanol based substance such as LIV
+45.
AIR VELOCITY SHOULD NOT BE LOWER THAN
2.0 m/s. For Hygienic and Clean AHU plate heat
exchangers, please use a brush to clean
the inlets and the outlets for normal
ventilation applications. Otherwise, use
7.8 Heat Wheel, Heat Pipe & Plate
compressed air or high-pressure water
Heat Exchanger
cleaning and disinfection.
The unit should be maintained in line with
the manufacturer recommendation. Please Please note that when using high pressure
refer installation and maintenance manual cleaning, do not spray the nozzle directly
for details. against the plates and pressure must be
kept below 100bar. This is to ensure the
For Hygienic and Clean AHU, the face of plates do not deform when removing the
the heat wheel should be inspected dirt.
regularly for dust and dirt to check if the
self-cleaning due to counter flow and When disinfecting, the detergent
rotation of the heat wheel is insufficient. recommended is Yes/Fairy detergent. This
For small amount of dirt, use a vacuum can be diluted with up to 75% water.
cleaner to clear off the dirt. For more Alternatively, you can use a LIV +45 for
stubborn dirt, use a compressed air to disinfection.
dislodge the dirt but handle with care so

7.9 Moisture Eliminator

Check the dirt accumulation at the blades,

remove and clean the blades if necessary.
Ensure the blades are correctly positioned
and not distorted.

7.10 Maintenance Plan for Air

Handling Units
The schedule provided in

- 20 -
 AHU with tarps and additional packaging
as necessary to protect them from
gives recommended maintenance contamination in harsh conditions.
intervals for the AHU unit (Guideline only).
Table 4 gives recommended maintenance Spare filters should be stored in a clean
intervals for Hygienic and Clean AHU units dry place that is protected from
(Guideline only). contamination and weather
Intervals are based upon normal running
conditions, in a moderate climate and 9. Trouble Shooting
assuming 12-hour running. Units operating
outside these guidelines may require Use Table to assist in trouble-shoot the
shorter or longer maintenance intervals. malfunction in Air Handling Unit operation.

7.11 Cleaning (Hygienic and Clean

AHU)
When cleaning the AHU, lint free cloths
and non-corrosive and silicone free
cleaning agents should be used unless
specified otherwise. Ensure dirt and dust
does not get into adjacent parts of the
system.

If disinfection is required for example in

hospital environments, the surfaces can be
treated with all-purpose, biodegradable
cleaning agents. However, avoid using
aluminum cleaners as they corrode the
surfaces of the metals. Only disinfectants
from the list of the Robert-KochInstitut
(RKI) or the Verbund für angewandte
Hygiene (VAH) should be used.
Only personnel that have passed the
hygienic qualification of at least category A
VDI 6022 part 4 are qualified to service
the AHU.

8. Storage
Please store the AHU in a dry place
protected from the weather. Cover the

Table 5 - Trouble shooting analysis

Symptom Probable Cause Recommended Action
Motor fail to start a) Blown fuse or open circuit breaker. a) Replace fuse or reset circuit breaker.
b) Improper wiring. b) Check wiring with diagram supplied.
c) Mechanical Failure. c) Check motor & drive rotate freely &
d) Missing control signal & improper bearing lubricant.
setting (EC fan). d) Check control signal & fan ID setting &
high/low level control source setting.
Motor stall a) Short circuit or phase to earth. a) Check line phases and terminal block
b) Overload motor. connection.
c) Low line voltage. b) Reduce system load.
d) Over tensioned belts. c) Check supplied voltage within motor
e) Misalign drive. voltage range.
d) Adjust belt tension.
e) Re-align drive.
Motor overheats a) Overloaded motor. a) Reduce load or replace larger motor.
b) Motor Fan dirty/ damage. b) Clean/ replace motor fan.
Low air volume after a) Fan rotating in wrong direction. a) Reverse any two phase connection at
start up b) Air damper not properly set. motor terminal.

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 c) Pressure drop by filter above b) Ensure system correctly balance & set.
recommended level. c) Change filters – (complete bank).
Excessive motor noise a) Motor mounting bolt loosen. a) Tighten motor mounting bolt.
b) Worn motor bearing. b) Replace bearing and seals.
Excessive noise from a) Worn fan or motor bearing. a) Replace bearing and seals.
unit b) Fan impeller rubbing on inlet cone or b) Check clearance or remove for repair.
cover. c) Check tension.
c) Incorrect drive belts tension.
Excessive vibration a) Fan impeller out of balance. a) Consult manufacturer.
b) Transport bracket not remove. b) Remove transport bracket.
c) Improper pulley alignment. c) Check pulley alignment.
d) Over-tensioned belts. d) Re-tension belts.
e) Vibration isolator damaged. e) Replace vibration isolator.
f) Motor shaft bend. f) Send the motor for repair.
g) Bad bearings. g) Replace bearing and seals.
h) Loosen bearing hold down bolt h) Tighten hold down bolt.
i) Fan & motor section not evenly i) Re-adjust and tighten.
supported on foundation. j) Conducts dynamic balancing.
j) Fan assembly’s tolerance is out of
range.
Bearing excessively hot a) Over-tensioned belts. a) Re-tension belts.
b) No lubricant. b) Apply lubricant
c) Over-lubricant. c) Purge and clean surface.
d) Misaligned bearing. d) Check & re-align shaft.
Water present in cooling a) Drain trap clog. a) Clean & clear clog.
coil drain pan or overflow b) Incorrect hydraulic trapping. b) Resize trap and check air break
arrangement.
Premature drive belts a) Improper tension or alignment. a) Check tension and alignment.
failure b) Incorrect belt being fitted. b) Replace with full set.
c) Dirt or grease on belts. c) Clean belt & pulley, check for grease
d) Belt rubbing. leak.
e) Worn sheaves. d) Remove obstruction.
e) Replace sheaves.
Belt swelling or softening a) Excessive contamination by oil, certain a) Replace with full set. Isolate the source
cutting fluids or rubber solvent. of contaminate.
Belt whipping during a) Incorrect tensioning. a) Re-tension belts.
running
Filter collapsing a) Filter block with dirt. a) Replace at advised dirty condition.
b) Air velocity too high. b) Check unit running conditions.
Note: The table is intended as a diagnostic aid.

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10. Appendix

10.1 Assembly of heat wheel

1. Heat wheel unit bottom section has already assembled with heat wheel support assembly
and heat wheel baffle bottom when delivered.
2. Placed the baffle centre to the penta-post / centre-post or panel.
3. Placed the heat wheel on the heat wheel support assembly in the bottom section from
opening on top/side, depends on the design.
4. Screw the heat wheel to the heat wheel support assy. by using self-drilling screws.
5. screwed the heat wheel baffle left/right and centre
6. Assemble the top cabinet section to the bottom section. If required, remove some panel to
facilitate assembly work of heat wheel. Screw the baffle left/right and centre to top section
cabinet.
7. Assemble the heat wheel baffle top.
8. Assembled back the remaining panels.

10.2 AHU Water Quality

Water quality requirements: Water softening treatment must be given in advance to prevent
scaling in the heat exchanger which may affect heat exchange effect. Moreover, water
without softening treatment may form scale in the pipe to increase water resistance which
will affect water flow and pump work efficiency.

Table 6 – Water Quality Requirements

Item Baseline Tendency
Value Corrosion Scaling
Benchmark pH (25°C) - 7.5 ~ 9.0 O O
items Conductivity (25°C) µS / cm <800 O O
Chloride Ion Cl- mg (Cl-) / L <200 O
Sulfate Ion SO4 2- 2-
mg(SO4 ) / L <200 O
Acid Consumption (pH=4.8) mg(CaCO3) / L <100 O
Total Harness mg(CaCO3) / L <200 O
Reference Ferrum Fe mg(Fe) / L <1.0 O O
items Sulphion S2- mg(S2-) / L 0 O
Ammonium Ion NH4+ mg(NH4+) / L <1.0 O
Silicon Oxide SiO2 mg(SiO2) / L <50 O
Note : O - factor related to the tendency of corrosion or scaling

10.3 AHU Commissioning Check Sheet

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AHU Commissioning Check Sheet
General Information

Project :
Unit Name :
Unit Model :
Unit Serial Number :
Installation Date :
Commissioning Date :

Initial Checking (Pre-start Up)

A) Fan Section

1. Are all fasteners tightened?

Answer: Yes No

2. Motor winding Resistances.

U1-U2: __________ V1-V2: __________ W1-W2: __________

3. Motor Megger Test.

U-Ground: __________ V-Ground: __________ W-Ground: _________

4. Are all electrical connections tight and of correct wiring?

Answer: Yes No

5. Correct incoming voltage that supplied to motor

L1-L2: __________ L2-L3: __________ L3-L1: __________

6. Rotate fan wheel whether it can rotate freely and without abnormal noise.
Answer: Yes No

7. Are pulleys aligned?

Answer: Yes No

8. Is belt tensioning correct?

Answer: Yes No Value:_______________

9. Are lock blower bases (blower base shipment bracket) removed?

Answer: Yes No

10. Are spring isolators adjusted to be same height?

Answer: Yes No

11. Ensure no construction debris or foreign material left inside AHU.

Answer: Yes No

12. Correct duct turning elbow direction and sufficient effective duct length.
Answer: Yes No
*Please attach duct layout from reference.

- 24 -
B) Coil Section

1. No construction debris or foreign material left inside AHU.

Answer: Yes No

2. Is the condensate drain trapped properly?

Answer: Yes No

3. Are pipe connections to coil header correct?

Answer: Yes No

4. Ensure good sealing around the coil header and drain pipe externally.
Answer: Yes No

C) Others

1. Make sure all dampers in AHU or ducting (if applicable) are in open position.
Answer: Yes No

2. Are filters installed in correct airflow direction?

Answer: Yes No

3. Are the AHU sections joined with section joint properly?

Answer: Yes No

4. Are the joining between AHU sections sealed properly?

Answer: Yes No

Start Up Checking

1. Is fan rotated in correct direction?

Answer: Yes No

1. Voltage that supplied to motor

L1-L2: __________ L2-L3: __________ L3-L1: __________

2. Motor current drawn per phase

L1: __________ L2: __________ L3: __________

3. Any abnormal noise?

Answer: Yes No

4. Any abnormal vibration?

Answer: Yes No Value:_______________

5. Measure and record total static pressure.

Value:_______________

6. Measure and record airflow.

Value:_______________

7. Measure and record fan RPM.

Value:_______________
Remark: Please refer IOM for details.

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