MANUAL

INSTALLATION
OPERATION
MAINTENANCE

Double Skin Modular Air Handling Unit

MODELS DM AHU
DS AHU
AHUR VRV AHU

VER: O-AHU01-JUN22-17

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. Trouble Shooting......................................................................................................... 18
9. Appendix .................................................................................................................... 20

1. General
1.4 Unit Decommissioning and
1.1 Foreword Disposal
This installation, operation and At the end of the unit’s useful life, a
maintenance manual is given as a guide to suitably qualified engineer should
user of air handling units. The manual decommission it. The parts/materials must
does not limit the users to add other be disposed of in a correct manner and
necessary procedures or services for the comply with the local laws and regulations.
continuous successful operation of this The unit components shall be disposed of
equipment. or recycled as appropriate in the correct
manner.
1.2 Warning Notes
2. Shipment
Warning and Important notes are
appearing at appropriate places in this The items should be carefully checked
instruction manual. Follow the warning against the bills of lading to ensure all
notes carefully to ensure correct operation crates have been received. All units should
of the equipment and personal safety. The be carefully inspected for damage when
manufacturer assumes no liability for received. Visible or concealed damage
installation, operation and maintenance should be reported immediately to the
undertaken by unqualified personnel. carrier and filed damage claims.

1.3 Occupational, Health and Safety WARNING

Practices DAMAGE OR LOSS OF PARTS IN
Connection and start-up of the unit should
SHIPMENT OR AT THE JOB SITE IS
be done in conditions, which are in
NOT THE RESPONSIBILITY OF
MANUFACTURER.
conformity with Local Codes and
Regulations, especially in the field of Air handling units are constructed with
operation of electrical devices. heavy-gauge steel or extruded aluminum
The mains voltage must not be turned on and are thoroughly inspected before
before the unit is connected to the leaving the factory. Care must be taken
protective system. It is forbidden to make during installation to prevent damage to
any repair and maintenance activities if units. Special care should be taken when
the power supply of the unit is not turned handling the blower section. All fans are
off. Servicing person, who makes repair or dynamically balanced before leaving the
maintenance of the unit must have proper factory. Rough handling can cause
qualifications resulting from the misalignment or sprung shaft. Therefore,
qualification certificate, which is blower fan and shaft should be carefully
determined by International, National or checked before commissioning to avoid
Local Codes and Regulation. more damage cause by unbalance fan.
Place of service should be equipped with Screws, bolts, nuts, etc. for assembly of
the necessary protective equipment, which sections are supplied in a bag attached to
provide safe maintenance.

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each section. All necessary gaskets are the forklift is too short then suitable
fixed in the factory. extensions should be used.

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
to prevent straps or cables from rubbing
the frame panel. Ensure stability and
Figure 2 - Transportation by forklift truck
balance when lifting the units and avoid
twisting or uneven lifting. Uneven lifting 4. Storage
may lead to accident or fatality which is
out of factory responsibility. Care should For external storage prior to installation,
be taken to prevent coil connections, drain the units must be protected from dust,
pan connection, damper operators and rain, constant sun exposure and rodents.
accessory section from damage. Although covered in shrink-wrapped
Do not push hard on the unit it self of on plastic sheeting, this is not intended for
the metal base. Use large wooden beam long-term storage and should be remove
to evenly distribute the force. Dropping as soon as it is offloaded. Unit therefore
the units will result in permanently should be more protected by tarpaulins or
damage of ball bearing, fan shaft or similar. Avoid exposed the units for coil
loosen coil from the mounting. connection damages by transient load.
The fan impeller or motor drive must be
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
AHU with metal base A FIXED LOCATION TO PREVENT
THEM FROM FALLING OVER.

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

AHU with wooden base
5.1 General
Figure 1 - Lifting method when offloading units
The system design and installation should
Transportation on the building site should follow accepted industrial practice, such as
be done using forklift truck or a crane described in the ASHRAE Handbook.
(See Figure 2). The forks must only be These units are not designed to be
applied under the unit base frame and not weatherproof (unless equipped with
against the panel. In case when fork of canopy) and therefore should not be

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installed outdoors. Flexible connections design to use section joint brackets to
should be used on the outlet and inlet combine two sections. Section joints for
duct connections for all units. A minimal cabinet and base frame are shown in
amount of air leakage is normal on the Figure 5 and Figure 6. (provided when
cabinet and it will not affect unit cabinets are joined by intermediate-post
performance. The air handling units are to intermediate-post arrangement)
not design to be suspended from the top
of the unit. Therefore, when the unit is
ceiling hung, make sure unit is supported
with a base rail of channel.

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
Figure 6 – Base Frame Section Joint
installed at a height that allows the
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
Figure 7 – Pre-installed section joints
(See Figure 4)
To join two sections, install and level the
first section in position, then push the
second section close to the first section
after the alignment is correct as shown in
Figure 8.

Figure 4 – Air handling unit Plinth Foundation

5.3 Section Joint

Units that shipped in sections must be
carefully assembled to desired unit
arrangement. The air handling units are

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 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
connected, then only followed by internal
section joints. Make sure all joint brackets
provided are tighten with bolt and nut as
shown in Figure 10. All the bolts and nuts Figure 11 – Section Joint for pentapost to pentapost
for the joining are provided and packed or different width cabinets
with the unit.

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Lastly, silicone sealant needs to apply to
in-between section to seal the gap.

5.4 Vibration Isolator

Air handling unit fans are supplied with
internal vibration isolators.

5.4.1 Spring Vibration Isolator

For model with spring isolators, temporary
transport brackets are fitted to prevent
Figure 14 – Restrained Spring Isolator
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
loosened. Turn the adjustment nut bolt
clockwise or anti-clockwise to decrease or
Figure 15 – Removing of U-Shaped Plate
increase the spring’s height. Tighten the
locking bolt after completing the
5.5 Arrangement (VRV AHU)
adjustment. (See Figure 13)
Control box and expansion valve kit are
installed on the air handling unit. Figure
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
Figure 12 – Removing of transport bracket for combination of Daikin condensing units
with air handling units” for further
instructions.
Standard Air Series VRV AHU

Figure 13 – Spring Isolator Adjustment

5.4.2 Restrained Vibration Isolator

The following is applied for plenum or Figure 16 - Standard Air Series VRV AHU Unit
other fan which is using restrained spring
isolator. (See Figure 14). 20mm U-shaped 1. Outdoor unit
plates are inserted between top plate and 2. Control box
base plate when shipped out from factory. 3. Air Handling unit
(See Figure 15). 4. Field piping (field supply)
5. Expansion valve kit
6. Outdoor unit power supply
7. Control box wiring

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8. Air handling unit thermistors contraction strains. Failure to comply will
9. Power supply and control wiring result in damage to the coils & headers.
for air handling unit and controller
10. Air thermistor control for AHU IMPORTANT
11. Remote controller TO AVOID DAMAGING THE COIL
CONNECTIONS AT COIL HEADER,
Outdoor Air Series VRV AHU IT IS ESSENTIAL TO HOLD THE
CONNECTOR / PIPE WITH TOOLS
WHILST APPLYING COUNTER
FORCE TO TIGHTEN THE JOINT.
(See Figure 18)

Figure 17- Outdoor Air Series VRV AHU Unit

1. Outdoor unit Figure 18 – Coil header connection method

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
11. Power supply and control wiring
for air handling unit and controller
12. Remote controller
Figure 19– Bulb orientation and position
5.6 Coil Installation/ Pipe Connection
Figure 19 shows the correct mounting
5.6.1 General method and the position of TXV sensing
bulb according to the piping size.
The coil will perform as per rating only if
the airflow is uniformly pass-through the IMPORTANT
coil surface. WRAP WET CLOTH AROUND PIPE
BEFORE PERFORM BRAZING TO
IMPORTANT PREVENT OVERHEAT PIPE AND
HIGH VELOCITY SPOTS ON THE DAMAGE COMPONENT AT PIPING.
COIL MAY CAUSE MOISTURE (Figure 20)
CARRY OVER. THEREFORE,
UNIFORM AIRFLOW ACROSS COIL
SURFACE IS CRUCIAL.

External pipe-work must be adequately

supported to ensure load-free towards coil
Figure 20 – wrap wet cloth before brazing
connections. Swing joints or flexible
fittings are to be provided in all piping
AFTER PIPE-WORK DONE, SITE
connections, particularly those adjacent to
INSTALLER MUST WRAP THE PIPE
heating source, to absorb expansion and
CONNECTION WITH INSULATION

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

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The flange or union is located to facilitate for the recommended depth and distance
coil removal. Flash trap may be used if of drain trap installation. (See Figure 22)
pressure differential between steam and Drain pan are not designed to be walked
condensate return exceeds 5 psi. Dirt leg on.
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
cannot lead to personal injury.
Steam piping and related components
must be installed in accordance with all
national and local codes, and in Figure 22 – Drain Trap Arrangement
accordance with the local authorities
having jurisdiction.
5.7 Electrical Installation
Electrical wiring design and installation on
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
Figure 21 – Standard steam pipe layout for horizontal separately.
coil arrangement

IMPORTANT
IMPORTANT MAKE SURE ALL THE ELECTRIC
ENSURE THAT THE SYSTEM IS POWER DISCONNECT AND
OFF OR THE COMPONENTS ARE SECURE FROM SWITCH ON
ISOLATED BEFORE BEGIN THE BEFORE DOING WIRING
WORK. EVEN AT LOW PRESSURE, CONNECTION
STEAM CAN CAUSE SERIOUS
BODY INJURY THAT MAY RESULT 5.7.1 Motor Connection
IN DEAD. The electric supply to the motor must
correspond to the rated voltage stated in
motor nameplate and be in conformance
5.6.7 Drain Pan Trap
with the National and Local Electric Code
Drain pipes and traps must be at least and Regulations. Motor supplied able to
same diameter as the drain pan operate within 10% tolerance from the
connection. Drain pan must be level to nameplate voltage. Motor connection
permit condensation from coil drain freely details are contained in the cover of the
motor terminal box. (See Figure 23). The

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fan section metal frame must be grounded. See Figure 25 for correct motor sheave
Suitable electrical protection isolator and fan sheave alignment.
should be installed to protect the motor Tensioning of the drive belt is achieved by
and other electrical equipment. moving the motor in relation to the fan
Flexible conduit must be used when wiring (See Figure 26). When inserting new belts,
up fan motors to allow the fan motor to do not force belts over grooves, Loosen
move freely on its anti-vibration mounts. the adjusting screw at motor base until
Cables passing through panels must be belt can slide smoothly over the grooves.
made with gland or grommet. When all belts are in position, proceed to
For inverter control, refer to the VFD adjust belt tension using the adjusting
manual for wire size and requirements. 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

Figure 24 – Motor Cabling

5.8 Drive Belt & Sheave

Figure 26 – Belt tensioning
Improper sheave alignment and belt
tension can cause excessive vibration,
premature failure of belts and bearings.

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 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 - -

5.9 Accessory Items of filter frame, sliding frame or universal

clip. Insert the filter into the frame by
5.9.1 Filter following airflow arrow indicated.
Air handling units can be supplied with flat
5.9.2 Mixing Box
filters and/or bag filters. There are 2 types

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Fresh air and return air dampers can be pipe/main cooling coil from top and side.
linked together and drives by the same (If applicable)
actuator if both are same size. Care must
be taken to ensure dampers are in open 5.9.6 Electric Heater
position while the fan is running whether
Power supply to electric heater and
they are integral with central plant control
electric connection is in accordance with
or associated ductwork under negative
wiring diagram in terminal box of electric
pressure condition.
heater.
5.9.3 Variable Pitch Pulley The rated voltage of electric heater is
240V, single phase.
Modifications of the pulley diameter must
be done when stationery by moving the
adjustable flange. Each complete rotation IMPORTANT
of one of the two disks results in a IT IS ADVICED TO INTERLOCK
variation of the pulley diameter. (See ELECTRICAL HEATER WITH
Table 2 & Figure 28) When the required BLOWER TO ENSURE HEATER IS
diameter is obtained, adjustable flange is NOT ENERGIZED WHEN THERE IS
locked by tighten the four clamp screws. NO AIR FLOW.
To get the same diameter in the two
grooves of pulleys, screw the two mobile 5.10. Ductwork
flanges on the central flange. Then
unscrew the two mobile flanges by the Connections to unit cabinet are made by
same number of turnings to get the site drilling into the frame on the unit inlet
required diameter. or fan discharge collar. This should be
Note that the belt centre line shifts when load-free toward cabinet collar when initial
diameter changes. Driven pulley may need positioned.
realignment. 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
rotation. Turning vanes should be used.
Discharge plenums or any abrupt change
in duct should be avoided.
Figure 28 – Variable Pitch Pulley

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)
Refer to assembly of heat wheel baffle
plates at Appendix 9.1 when the heat
wheel section not able to ship in complete
build up.
Figure 29 – Discharge duct layout
5.9.5 Heat Pipe
Notes:
After installation of Heat Pipe with refers
1. Elbows should not be closer than
to manufacturer recommendations, site
2-1/2 times the Duct Equivalent
installer to install heat pipe baffle plates at
Diameter. (Refer to Formula 1)
site, this is to avoid air bypass heat

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 2. Dampers should be placed at least
fan diameters downstream of the
fan discharge.

Figure 23 – Front view of Return duct to be large

enough to cover exposed area

Formula 1 - Duct Equivalent Diameter

All duct joints, edges, opening area of top

roof (example: top discharge, top damper Figure 24 – Side view of Return duct to be large
enough to cover exposed area
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). 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
provided for assembly at site.

5.12 Component Removal and

Replacement

Figure 30 – Site to seal gap between roof and duct 5.12.1 Panel Removal
To remove side or top panel, simply
unscrew the fasteners located along the
aluminum clip on the frame of Air
Handling unit cabinet. Once the aluminum
clips are removed, lift the panel off.

5.12.2 Fan / Motor

The fan shaft, motor and drive
components can be removed and replace
Figure 22 – All edge to be seal by site if the flange
was sent separately / unit is CKD
through the access door opening or side
panel removal if additional access required.
For outdoor unit, the return duct should For fan replacement, the entire fan
be large enough to cover the exposed assembly can be pulled out from side or
area of AHU to prevent rain water from front (for top discharge) of the cabinet.
seeping into the unit. Dismantle the intermediate fan supports
and canvas follow by loosening bolts &
nuts at motor and drive belts. Then
remove the belts and nuts from Fan

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mounting frame. Take out the fan and WARNING
replace with new fan with care. Re- ISOLATE THE ELECTRICAL &
connect the shaft and bearings and fan MECHANICAL ENERGY SOURCE
assembly. AND PADLOCK THE SWITCH
BEFORE SERVICING THE FANS
5.12.3 Coil AND MOTORS.

The coil can be pulled out from side or top

of cabinet. The coil is fastened with bolts 6.1.2 Fan / Motor
and nuts on the coil support bracket at the
end plate and baffle plate. Before removal Make sure the fan impeller can rotate
of coil, ensure the piping connections at freely by hand. Check the tension and
header are disconnected. In case where alignment of the belt drive.
two coils are stacking, remove the drip Check motor connections and make sure
pan and join brackets which holding the correct voltage is supplied. If standby
two coils together. motor is available, make sure only one
For DX coils, it is advisable that the motor to power source.
refrigerant is to be pumped into the Seal end of fan motor conduit (if
condenser. If this is not possible, applicable) and the motor terminal box
refrigerant shall be purged out. with silicon sealant.
VFD/Frequency Inverter for TEFC motor
can only vary the frequency within 30 to
WARNING 60 Hz in order to control the motor
DO NOT HEAT ANY PART ON DX rotation speed. For VFD setup, make sure
COIL IF REFRIGERANT STILL IN the VFD settings according to
THE SYSTEM. HEATING UP WILL recommendations at VFD manual.
CAUSE DANGER OF HIGH When multiple fan with multiple VFDs,
PRESSURE INSIDE THE COILS. fans must set up to always start
simultaneously and with same speed.
6. Commissioning and Operation
6.1.3 Fan Array
6.1 Pre-run Check
Fan array is available for EC plug fan.
6.1.1 Preparation Ensure all fans are control to run
simultaneously and with same speed.
The complete air handling unit and all Fans running at unequal speeds can result
accessory components should be uneven airflow that cause performance,
thoroughly cleaned and all dust & debris sound, vibration problems that lead to
completely removed. failure.
Make sure that all transport brackets and In case one of the fan is down, blank off
packing have been removed. plate shall be temporarily installed on the
Ensure all screws, bolts and nuts on AHU nonfunctional fan to prevent air re-
are secured tightly (not loose during AHU circulation while waiting fan replacement
transportation or handling). (See Figure 25). If present of differential
Ensure all panel and belt drive settings are pressure controller, ensure the pressure
secured due to change during shipment or tube of nonfunctional fan is capped and
installation. amend the setting of controller accordingly.
In case additional equipment is installed at
site, ensure air leaking spots are being
seal with additional baffle plates or seal
with silicone to prevent air bypassing.
The lamination films stick on the PU panel
act as protection film for PU panel. It is
normal that the films torn or dirt from the
protection purpose. Peel off the lamination
film when the unit is in position.

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 temperature. Pressure and temperature
limitations can be referred to COC of
vendor provide.

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
Figure 25 - Fan Array with Blank-off Plate section joints are in place.

6.1.4 Vibration Isolator Mount 6.1.9 Electric Heater

Ensure the vibration isolator mounts and Electric Heater – Before starting-up,
flexible connections allow the fan and ensure that the air flow through the
motor to move freely without constrain. heater should not be lower than 2.0 m/s
For the fan with Restrained Spring Isolator, to avoid overheating heater. Optional
ensure that the Alu Angle plates are items of airflow switch and differential
removed from the restrained spring pressure switch (50-500Pa setpoint range)
isolator before commissioning. only indicate fan is running. Setting
adjusting is necessary in some situations
IMPORTANT for proper operation.
The clearance between flanges
of “Top plate” and “Base plate” WARNING
for restrained spring isolator FOR 380-415V/3PH, STAR
should be approximately 10- CONNECTION WITHOUT NEUTRAL
20mm. (Figure 26), UNBALANCED PHASE
VOLTAGE MAY CAUSE DAMAGE
6.1.5 Coils ON THE ELECTRIC HEATER.
Check the pipe-work to coil is correctly
connected and the fins are free from
foreign matter or damage.
Check that the condensate drain is trap.
Ensure good sealing of silicon around the
coil headers and drain pipe.
Make sure operating pressure is within
design limits.

6.1.6 Steam Coils

Proper air distribution is vital to coil Figure 26 - Wiring Diagram without Neutral
performance. Air velocity anywhere on the
FOR 380-415V/3PH, STAR
coil should not vary
CONNECTION WITH NEUTRAL
by more than 15% from the average
(Figure 27), NEUTRAL POINT MUST
velocity. Air velocities should be
BE CONNECTED IN ACCORDANCE
maintained between 200 and 1500 feet
WITH WIRING DIARGRAM IN
per minute. Operating pressures must be
ORDER TO CARRY CURRENT DUE
at or below the maximum operating
TO UNBALANCED PHASE
pressure for the coil at steam VOLTAGE.

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IMPORTANT e. Heat Pipe – Ensure installations are as
SAFETY THERMOSTAT IS FOR per manufacturer recommendation.
OVERHEATING PROTECTION
ONLY, NOT FOR CONTROL
PURPOSE. DEFAULT SETPOINT IS 6.3 After first 48 hours of operation
60˚C. a. Make sure complete isolate the
IT MUST BE CONNECTED TO Electrical source.
CONTACTOR (WHETHER b. Re-check and Re-tension the drive
SUPPLIED BY FACTORY OR SITE) belts due to stretch.
TO CUT-OFF HEATER IN CASE OF c. Check and adjust the pulley alignment
OVERHEATING HEATER. to ensure the motor fixing is properly
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
Figure 27 - Wiring Diagram with Neutral SECTION NOT TO EXCEED 1040F
(400C).
6.2 Start-up Check
6.4 Fan Operating Limits
Competent, well-trained personnel must
be employed in the following operations to The fan operating limits for forward curve
ensure Safety Rules and Regulation being and airfoil fan are shown on the Table 3.
adhered to at all time. Total static pressure should be limited to
1000 Pa for forward curve and 1500 Pa for
backward curve/airfoil fan.
IMPORTANT
Table 3 - Fan Operating limits
FAILURE TO PROVIDE MOTOR
Backward
OVERLOAD PROTECTION COULD Blower
Forward Curved
Curve/Airfoil
RESULT IN MOTOR DAMAGE. Size Max. Max. Max. Max.
CONNECT THE MOTOR TO AN RPM kW RPM kW
OVERLOAD PROTECTIVE DEVICE 200 3800 3 5700 2
225 3400 4 5400 3
THAT IS RATED IN COMPLIANCE
250 2600 4 4400 3
WITH THE APPLICABLE CODE. 280 2400 6 3900 4
315 2100 6 3500 5
355 1900 8 3100 6
a. Check the rotation of the fan impeller. 400 1700 8 2700 8
If the fan rotates in opposite direction 450 1400 10 2500 11
from desire, reverse any two phase 500 1200 11 2200 11
connection at motor terminal. 560 1100 15 1900 15
b. Check that there is no unusual noise 630 900 15 1700 15
710 850 25 1500 30
or vibration. Stop and investigate if
800 750 25 1350 30
found. (refer to section 8) 900 650 30 1150 35
c. Measure the voltage and drawn 1000 600 30 1050 35
current of the motor. The drawn
current must not exceed the full load 6.5 Installation of VRV AHU Control
current mentioned at motor Box (EKEQ)
nameplate.
For installation VRV AHU Control Box,
d. Heat Wheel – Ensure the heat wheel
please refer to the Installation And
can rotate freely by hand.
Operation Manual in VRV ED or refer to
manufacturer for advices.

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 If unit equipped with belt guard, check
6.6 MicroTech III Commissioning
that it is fitted correctly and secure.
MicroTech III is an option. For If there is any undue noise or knocking
commissioning of MicroTech III, please from bearing, replace both bearings. Fan
refer to the MicroTech III Commissioning bearing are grease for life, but larger units
Manual in VRV ED or refer to with standard bearing require semi-annual
manufacturer for advices. or annual lubrication at bearing greasing
nipple. Recommended lubricants are
Standard Din 51823, K3N or ISO XM2.
6.7 DMA6 Door Opening 7.2 Drive Belt
Belts that are split or have frayed edges or
any other sign of damage (rubber shred
on floor) must be replaced in full set.

IMPORTANT
DURING MAINTENANCE AND
SERVICING, UNIT MUST BE
COMPLETELY ISOLATED AND
PRECAUTIONS TAKEN TO
Figure 28 – Universal Handle PREVENT ACCIDENT FROM
HAPPENING.
DMA6 doors with the universal handle
shown in figure 37 are able to open from Check the belt tension and alignment, re-
the left or right direction or removable. If tension and re-align if necessary. Refer to
opening door while the fan is running, Section 5.7 for belt tensioning procedure.
make sure to open handles on one side New belt drive must be re-tensioned after
only. For example, either only open all the first 48 hours of operation.
handles on the left or only open all For replacement of belts, remove the belt
handles on the right side. guard before starting work. To change the
belts, first loosen the adjusting screw and
move the motor towards the fan to enable
old belts to be taken off and put on of
new belts. (Matched belts must be used)
Tension the belts by following instruction
at Section 5.7.

7.3 Coil Section

Periodic cleaning of coils is required. Dirty
coils have tendency to increase airside
Figure 29 – DMA6 Door Opening Procedure while fan
running
pressure drops and reduce cooling/heating
efficiency. Dry cleaning is done by using a
powerful vacuum cleaner on the dust-
7. Maintenance accumulated side. If coil is very dirty, coils
need to be removed for wet cleaning by
7.1 Fan / Motor trained personnel. Ensure coil fins are not
Check for soiling, corrosion, damage and damage when performing dry/wet
tendency of excessive vibration. cleaning. In the event that fin edges have
Check that all bolts and nuts and flexible been bent, treat with aid of a coil comb.
connections are securely fixed. Check that frost protection is working
Check that vibration isolator mounts are before starting of each winter season.
functioning well. Ensure the frost sensor is correctly
Inspect for any obstructions or blockages installed and working within desired
at air intakes and discharges. temperature range.
Check fan bearings are secured and no For direct expansion coils, do not use hot
undue noise by observe/listen using metal water or steam to clean these coils. During
bar as a conductor. normal operation, the fin block must not

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 be ice up. If this occurs, check the before using any cleaning fluid. Clean the
refrigeration system. coil from the leaving airside so that foreign
Check that drain pan and drain trap are material will be washed out of the coil
free from blockage and water rather than pushed further in. Internal coil
accumulation at pan. maintenance consists primarily of
preventing scale and corrosion. This is
7.4 Steam Coil Section accomplished through aggressive boiler
Scheduled plant maintenance should water treatment, removal of dissolved
include the draining and flushing of the oxygen, and the removal or non-
condensate drip legs and sediment traps condensable gasses such as carbon
as well as inspection of condensate traps, dioxide.
vacuum breakers, air vents, and valves.
Boiler water analysis should also be 7.5 Filter Section
performed on a regular basis. To During system start up, filters are likely to
continually deliver full heating capacity, become rapidly blocked.
both the external and internal heat
transfer surfaces must be maintained as Disposable filters and bag filters must be
clean and corrosion free as possible. The replaced each time when pressure drop
finned surface can be maintained by the reaches the indicated dirty condition by
use and constant inspection of pre-filters. D.M. Manometer. Washable filters must be
The filters should be replaced as needed. cleaned periodically.
Should the finned surface become fouled,
the coil can be cleaned using commercially 7.6 Dampers
available coil cleaning fluids. Caution Check for dirt accumulation, damage and
should be exercised in selecting the sign of corrosion. Clean with cloth or high
cleaning solution as well as the cleaning pressure air. Check damper blade turning
equipment. Improper selection can result manually or central control for smooth
in damage to the coil and health hazards. operation.
Be sure to carefully read and follow the
cleaner manufacturer’s recommendations

Table 4 - 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 ●

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 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 ●

7.7 Electric Heater Check the dirt accumulation at the blades,

remove and clean the blades if necessary.
Check for dirt accumulation and clean if
Ensure the blades are correctly positioned
necessary with a soft brush. Check the
and not distorted.
safety control, cables and connections
operation.
7.10 Maintenance Plan for Air
Handling Units
IMPORTANT
The schedule provided in
AIR VELOCITY SHOULD NOT BE
LOWER THAN 2.0 m/s. Table 4 gives recommended maintenance
intervals for the AHU unit (Guideline only).
7.8 Heat Wheel & Heat Pipe Intervals are based upon normal running
The unit should be maintained in line with conditions, in a moderate climate and
the manufacturer recommendation. Please assuming 12-hour running. Units operating
refer installation and maintenance manual outside these guidelines may require
for details. shorter or longer maintenance intervals.

8. Trouble Shooting
7.9 Moisture Eliminator Use Table 5 to assist in trouble-shoot the
malfunction in Air Handling Unit operation.

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 &
bearing lubricant.
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.
c) Pressure drop by filter above b) Ensure system correctly balance & set.
recommended level.

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 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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9. Appendix

9.1 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.

9.2 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

9.3 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.

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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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