Bluestar AHU

Double Skin Air Handling Units
Screwless Cabinet for low leakage and assured Indoor Air Quality
Users Manual
DOUBLE SKIN AHUs SCREWLESS
First published February 2009

No part of this publication may be reproduced in any
manner whatsoever without permission in writing from the
President, Electro Mechanical Projects,
Blue Star Limited.
While due care has been taken to avoid errors or misinterpretation,
Blue Star Limited is neither liable nor responsible for consequence
of any action taken, on the basis of this publication.
Since ASHRAE standards use the FPS system, FPS nomenclature
is used in some places in this publication for convenient reference.
Published by Blue Star Limited, Airconditioning Projects Division.
For restricted circulation only. Not for sale.
USER'S MANUAL
CONTENTS
Introduction ..................................................................................................................................
Features of Double Skin Horizontal Floor Mounted AHU ...........................................................
Technical Data .............................................................................................................................
Features of Double Skin Vertical Floor Mounted AHU ................................................................ 10

Technical Data ............................................................................................................................. 11
Features of Double Skin Ceiling Suspended AHU ...................................................................... 13
Technical Data ............................................................................................................................. 14
Transportation and Storage ......................................................................................................... 25
Packing List (typical) ................................................................................................................... 27
Double Skin Horizontal AHU Assembly Procedure ..................................................................... 33
Assembly the AHU ....................................................................................................................... 35
Recommended Tools ................................................................................................................... 50
Electrical Information .................................................................................................................. 51
Cooling and Heating Coil Installation .......................................................................................... 52
Condensate Drain Piping ............................................................................................................ 54
Air System ................................................................................................................................... 55
Pre-Start Up ................................................................................................................................. 56
Operation ..................................................................................................................................... 58
Maintenance ................................................................................................................................ 59
Wintering System Components .................................................................................................. 61
Removal or Reinstallation of Components ................................................................................. 62
Installation of Double Skin Vertical AHU ..................................................................................... 64
Installation of Double Skin Ceiling Suspended AHU .................................................................. 65
Troubleshooting ........................................................................................................................... 66
Spare Parts List ........................................................................................................................... 69
Field Feed Back Card .................................................................................................................. 82
Warranty Claim ............................................................................................................................ 84
Blue Star Service Centres .......................................................................................................... 86
Introduction
Double Skin Air Handling Units with Screwless Cabinet
For assured air quality
Blue Star, Indias largest and preferred airconditioning company has been
providing expert cooling solutions for nearly six decades. It is with this
expertise we bring to you a wide range of air handling units manufactured
at our own world-class factories.
The Double Skin Air Handling Unit, as the name suggests has an outer
casing made of sandwicthed panels, resulting in low noise, sturdy
construction and better thermal insulation. These have been completely
redesigned in Screwless Cabinet construction. Taper Wedges are used
for fixing and locking of the insulated panels with aluminum frame.
Advantages of new Screwless Cabinet construction:
Reliability and Longer Life

Rigid framework comprises an assembly of externally rounded extruded aluminum anodized profiles that
are anticorrosive and fiberglass corner joints that avoid condensation at corners. The panels are pressure
injected with polyurethane foam, using CFC free R-141 b blowing agent. High and uniform PUF density of 38
2 kg/m3 provides better thermal conductivity and sound attenuation properties.
Better Aesthetics
No gaps and level difference at panel joints. Fixing screws are avoided in assembling panels. The colour of
the AHU is texture finish gray.
High Indoor Air Quality

Double skin panel construction allows easy inspection, cleaning and maintenance of the smooth inner surface,
reducing the risk of dirt and bacteria accumulation. There is no erosion of internal insulation material to
contaminate the air stream. Improved Panel frame arrangement by overlapping wedge and special gasket
reduces air leaks into the casing significantly. This maintains the Indoor Air Quality (IAQ) and also provides
the better thermal and acoustic performance.
Low Noise
Usage of double skin casing, imported AMCA certified fans, anti vibration spring isolators, which isolated the
fan from the main structure thus minimizing vibration and results in low operation noise.
Energy Efficiency
The units utilize Blue Star free flow coils (Coil Nomenclature CDW, CDX, YDW, YDX). The Fins of these coils
have a mild ripple, die formed channels to improve heat transfer efficiency and hence are energy efficient.
USER'S MANUAL
Ease of Assembly and Maintenance

New construction leads to faster assembly. The coil is placed on the sliding channel for ease in service and
maintenance.
Reduces Air bypass in Filter Section

New Design of Filter Frame flush with the cabinet minimizes the chance of air
leakage between the filter frame and the casing.
Standard Filter Sizes

The filter sizes are standardized to the internationally recognized standard of four
sizes in all horizontal AHUs. The filters are pleated to provide more filtration area.
Compact Design
Floor Mounted Equipment footprint has been optimized to make the units more compact. Key components
like Cooling Coil, Blower Assembly and Filters are redesigned for compact design and better performance.
Features
Double Skin Horizontal Air Handling Units Floor Mounted Type
The horizontal floor mounted units are ideal units to handle high air quantity. The composite design sections
offer both sturdy construction and flexible combination of components such as coils, filters, etc to suit specific
applications hence they are widely used in industrial, clean room and large commercial airconditioning. As all
major components are aligned to the base tray, it is maintenance and service friendly.
These Double Skin Horizontal Floor mounted Air Handling Units are available in 37 models with air quantity
varying from 3250 to 60600 CMH.
Standard features of the Units:

a. Casing
Rigid framework, comprising of smooth, rounded extruded aluminium anodized profiles with fibre glass corner
joints.
Double skin sandwiched panels:

- Outer skin: 0.5 mm pre-painted galvanized sheet steel.
- Inner skin: 0.5 mm plain galvanized sheet steel with 180 GSM Zinc Coating.
Panels are 24+1 mm thick, pressure injected with polyurethane foam, using CFC-free R-141b blowing agent.
Uniform PUF density of 38+/- 2 kg/Cu.m provides better thermal insulation (K factor not exceeding
0.02 W/m-C.)
Insulated Panels are fixed on the aluminium frame using overlap design wedges. The design avoids use of
screws for assembly of panels. 3 mm thick gasket is fixed on frame below the panels. The construction leads
to improved air tightness of the cabinet and hence results in better Indoor Air Quality. It also improves the
Thermal and Acoustic Performance.
The AHU base frame is of 14 G GSS and of 80 mm height.
Drain pan is made of 0.8 mm thick, Powder Coated Galvanized Sheet steel. The drain pan is insulated with
5 mm thick closed cell elastomeric Insulation to avoid surface condensation.
USER'S MANUAL
b. Cooling Coils
The Coils are made of Copper tube of thickness 0.36mm and the aluminium fins of thickness 0.12mm.
Free flow fin configuration is formed in plain aluminium fin stock with mild ripples die formed channels provide
excellent heat transfer capability with low air side Pressure drop. Mechanical expansion of copper tubes with
aluminum fins assure good thermal bonding and improve heat transfer. Coils are complete with copper headers
provided with air vent and drain plugs. In and out connections are of mild steel for convenience to connect to
water line at site.
The coils are placed on sliding channels for ease in service and maintenance.
c. Fans
Fans are of double inlet, double width type with forward curved impeller.
The scroll and impeller are made of galvanized steel sheet.
The fans are AMCA certified and are statically and dynamically balanced.
The whole fan assembly is trim-balanced to ISO1940 & AMCA 204 G2.5 Standard.
Belt-Driven Fans are supplied with three phase, 415V, 50Hz, TEFC squirrel cage Hindustan / Spartan
(A batiliboi group of company) make motor with IP55 protection and with Class F insulation.
d. Pre-Filters
The Pre filter is 50 mm deep in box type construction of efficiency 90% down to 10 microns confirming to
EU 3 class of EN779 specification. The filter media is synthetic, non-woven fire retardant type.
Pre-filter is pleated to provide more filtration area. The Pleated air filter incorporates a 100% synthetic thermal
bonded media with an average arresting exceeding 80% by weight. The filter media is bonded to a metal grid
on the air exiting side, Preventing fluttering and maintaining uniformity of the pleats. The filter pack is enclosed
in an aluminium frame.
e. Hinges and Handles
The fan section is provided with an access door for ease in serviceability of fan and
motor. Nylon handles can be operated from both inside and outside the casing and
are user-friendly.
f. View Port and Marine Lamp
View Port is provided on fan door panel which helps to monitor fan and motor status.
Marine lamp provides easy visibility. This needs to be electricity connected at site.
g. Limit Switch
Door limit switch automatically trips the motor when the door is opened and hence stop the blower.
This needs to be connected up in series with no volt coil of the AHU starter.
h. Damper
Every AHU is supplied with a factory fitted GI, powder coated, opposed blade volume control damper
to facilitate air balancing.
2700
2700
2700
2700
2700
2700
2935
2935
2935
2935
DHW4- 445 -C
DHW4- 455 -C
DHW4- 470 -C
DHW4- 490 -C
DHW4- 500 -C
DHW4- 520 -C
DHW4- 540 -C
DHW4- 570 -C
DHW4- 600 -C
2540
DHW4- 340 -C
DHW4- 430 -C
2335
DHW4- 325 -C
2700
2335
DHW4- 300 -C
2635
2335
DHW4- 290 -C
DHW4- 410 -C
2390
DHW4- 265 -C
DHW4- 390 -C
2175
DHW4- 255 -C
2635
2175
DHW4- 240 -C
2635
2175
DHW4- 230 -C
DHW4- 370 -C
2175
DHW4- 220 -C
DHW4- 355 -C
2035
1865
DHW4- 150 -C
2035
2175
DHW4- 135 -C
DHW4- 200 -C
1670
DHW4- 190 -C
1670
DHW4- 110 -C
DHW4- 120 -C
1865
1670
DHW4- 100 -C
2035
1510
DHW4- 080 -C
DHW4- 175 -C
1715
1510
DHW4- 070 -C
DHW4- 160 -C
1510
1370
DHW4- 050 -C
900
3290
3290
2935
2935
3290
3290
3290
3000
2935
2935
2635
2635
2635
2635
2635
2635
2390
2390
2220
2175
2035
2015
2015
2015
2015
1875
1875
1875
1460
1715
1370
1370
1105
1105
1370
1370
mm
mm
DHW4- 035 -C
Width
2575
2465
2510
2510
2130
2130
2130
2150
2210
2210
2205
2150
2150
2150
1890
1815
1890
1890
1890
1815
1815
1815
1815
1575
1495
1475
1495
1495
1515
1200
1200
1200
1170
950
950
885
885
mm
Height
AHU Overall Dimension
Length
DHW4- 040 -C
AHU MODEL
2896
2896
2642
2642
2946
2896
2794
2692
2642
2591
2337
2337
2286
2337
2337
2337
2083
1981
1829
1829
1727
1676
1575
1727
1727
1575
1473
1422
1168
1422
1372
1168
1067
1067
813
711
559
mm
Fin
Length
2286
2159
2223
2159
1842
1842
1842
1842
1842
1842
1905
1842
1778
1651
1588
1524
1588
1588
1588
1524
1524
1524
1524
1270
1207
1207
1207
1143
1270
953
889
953
889
699
699
635
635
mm
Fin
High
6.62
6.25
5.87
5.70
5.43
5.33
5.15
4.96
4.86
4.77
4.45
4.30
4.06
3.86
3.71
3.56
3.31
3.15
2.90
2.79
2.63
2.55
2.40
2.19
2.08
1.90
1.78
1.63
1.48
1.35
1.22
1.11
0.95
0.75
0.57
0.45
0.35
Sq.m.
Coil
Area
35625
33646
31597
30694
29400
28698
27650
26684
26181
25300
23958
23160
21875
20800
19965
19167
17795
16927
15625
15000
14167
13750
12904
11806
11200
10226
9566
8825
7986
7292
6470
5990
4861
4010
3056
2431
1910
CFM
60563
57198
53715
52180
49980
48787
47005
45363
44508
43010
40729
39372
37188
35360
33941
32584
30252
28776
26563
25500
24084
23375
21937
20070
19040
17384
16262
15003
13576
12396
10999
10183
8264
6817
5195
4133
3247
CMH
Air Qty
Standard Coil Size
FDA 1000 TM
FDA 1000 TM
FDA 1000 TM
FDA 1000 TM
FDA 900 TM
FDA 900 TM
FDA 900 TM
FDA 900 TM
FDA 900 TM
FDA 900 TM
FDA 900 TM
FDA 800 TM
FDA 800 TM
FDA 800 TM
FDA 800 TM
FDA 710 CM
FDA 710 CM
FDA 710 CM
FDA 710 CM
FDA 630 CM
FDA 630 CM
FDA 630 CM
FDA 630 CM
FDA 560 CM
FDA 560 CM
FDA 560 CM
FDA 500 CM
FDA 500 CM
FDA 500 CM
FDA 450 CM
FDA 450 CM
KAT18 X 18CM
KAT18 X 13CM
KAT15 X 15CM
KAT12 X 12CM
KAT12 X 9CM
KAT10 X 10CM
Kruger
1266 * 1266
1266 * 1266
1266 * 1266
1266 * 1266
1130 * 1130
1130 * 1130
1130 * 1130
1130 * 1130
1130 * 1130
1130 * 1130
1130 * 1130
1006 * 1006
1006 * 1006
1006 * 1006
1006 * 1006
898 * 898
898 * 898
898 * 898
898 * 898
800 * 800
800 * 800
800 * 800
800 * 800
714 * 714
714 * 714
714 * 714
638 * 638
638 * 638
638 * 638
568 * 568
568 * 568
557 * 478
430 * 478
471 * 404
395 * 341
309 * 341
331 * 289
W - mm X
H - mm
Fan
Opening
Fan & Motor Details

Fan Model
Double Skin Floor Mounted Horizontal Draw Through Units

40mm TSP
10.49
9.91
9.31
9.04
10.87
10.61
10.22
9.87
9.68
9.35
8.86
10.81
10.21
9.7
9.31
11.23
10.42
9.92
9.15
11.07
10.45
10.14
9.55
10.93
10.37
9.47
11.1
10.24
9.26
10.67
9.47
10.62
11.17
9.95
10.71
10.89
9.43
m/sec.
65.9%
66.1%
65.8%
65.5%
63.3%
63.7%
64.3%
64.7%
64.9%
64.9%
64.5%
63.3%
63.7%
64.6%
64.9%
66.0%
67.0%
67.4%
68.0%
63.2%
63.7%
63.8%
63.9%
66.3%
67.0%
67.5%
62.7%
63.4%
63.8%
64.3%
64.6%
67.3%
68.6%
64.7%
62.0%
63.4%
63.3%
15
15
11
11
11
11
11
11
11
11
11
11
9.3
7.5
7.5
7.5
7.5
7.5
5.5
7.5
5.5
5.5
5.5
5.5
5.5
5.5
5.5
3.7
3.7
3.7
3.7
2.2
2.2
1.5
1.5
1.1
0.75
kW
65.9%
65.2%
63.9%
63.1%
64.8%
64.9%
64.8%
64.4%
64.0%
63.2%
61.8%
64.7%
64.9%
64.7%
64.4%
67.3%
67.9%
68.2%
67.4%
63.9%
64.0%
64.0%
64.0%
67.4%
67.4%
66.2%
63.5%
63.8%
63.3%
64.7%
62.9%
65.8%
69.2%
63.8%
60.9%
64.5%
61.0%
18.5
15
15
15
15
15
15
15
15
15
11
11
11
11
11
9.3
7.5
7.5
7.5
7.5
7.5
7.5
7.5
5.5
5.5
5.5
5.5
5.5
5.5
3.7
3.7
3.7
2.2
2.2
1.5
1.5
1.1
kW
Motor
Power
50 mm TSP
Fan Outlet
Fan
Motor
Fan
Velocity Effieiency Power Efficiency
1550
1525
1500
1465
1425
1400
1380
1365
1340
1325
1300
1200
1180
1160
1140
1060
850
840
750
735
715
705
675
615
590
560
505
475
450
435
425
415
350
340
245
235
200
Kg.
With 4 RD
Coil
1685
1650
1625
1590
1565
1540
1525
1500
1480
1465
1440
1325
1300
1285
1265
1150
940
925
825
800
785
775
735
655
640
615
555
525
500
470
460
445
375
365
260
250
215
Kg.
With 6 RD
Coil
Operating Wt. (Approx)
Technical Specifications
DHW4 - 035-C
DHW4 - 040-C
DHW4 - 050-C
DHW4 - 070-C
DHW4 - 080-C
DHW4 - 100-C
DHW4 - 110-C
DHW4 - 120-C
DHW4 - 135-C
DHW4 - 150-C
DHW4 - 160-C
DHW4 - 175-C
DHW4 - 190-C
DHW4 - 200-C
DHW4 - 220-C
DHW4 - 230-C
DHW4 - 240-C
DHW4 - 255-C
DHW4 - 265-C
DHW4 - 290 -C
DHW4 - 300-C
DHW4 - 325-C
DHW4 - 340-C
DHW4 - 355-C
DHW4 - 370-C
DHW4 - 390-C
DHW4 - 410-C
DHW4- 430-C
DHW4- 445-C
DHW4- 455-C
DHW4- 470-C
DHW4- 490-C
DHW4- 500-C
DHW4- 520-C
DHW4- 540-C
DHW4- 570-C
DHW4- 600-C
AHU MODEL
1910
2431
3056
4010
4861
5990
6470
7292
7986
8825
9566
10226
11200
11806
12940
13750
14167
15000
15625
16927
17795
19167
19965
20800
21875
23160
23958
25300
26181
26684
27650
28698
29400
30694
31597
33646
35625
CFM
3247
4133
5195
6817
8264
10183
10999
12396
13576
15003
16262
17384
19040
20070
21998
23375
24084
25500
26563
28776
30252
32584
33941
35360
37188
39372
40729
43010
44508
45363
47005
48787
49980
52180
53715
57198
60563
CMH
Air Qty
22
28
32
42
42
46
54
56
46
56
58
62
68
68
62
66
68
72
72
78
82
92
92
92
90
92
92
102
104
106
110
114
116
104
104
114
114
Inch
Fin
20
20
22
22
28
30
28
30
40
36
38
38
38
40
48
48
48
48
26+24
26+24
26+24
48
26+24
26+26
28+28
30+28
30+30
30+28
30+28
30+28
30+28
30+28
30+28
34+34
36+34
34+34
36+36
3.82
4.86
6.11
8.02
10.21
11.98
13.13
14.58
15.97
17.50
19.13
20.45
22.43
23.61
25.83
27.50
28.33
30.00
31.25
33.85
35.59
38.33
39.93
41.53
43.75
46.32
47.92
51.35
52.36
53.37
55.38
57.40
58.40
61.39
63.19
67.29
71.25
Sq.Ft.
Tube High Coil Area

Length
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1/4
1/2
1/2
1/2
2
2
2
2
2
2
2
2
2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
2
2
2
2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
Inch1
Coil In/Out
Size
Standard Coil Size
D
D
D
D
D
D
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
4 Row
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
6 Row
Coil Circuit
1
1
1
2
2
2
2
2
4
4
4
4
6
6
6
6
6
6
6
6
6
8
8
12
12
12
12
12
12
12
15
15
15
12
12
15
15
4
4
5
5
3
3
3
3
3
3
3
4
4
2
2
2
2
610 X 305
Qty
3
3
3
3
2
2
2
2
2
1
1
1
1
305 X 610
Filter sizes in mm (W X H)
610 X 610
Double Skin Floor Mounted Horizontal Draw Through Units
1
1
1
1
1
1
305 X 305
USER'S MANUAL
Features
Vertical Double Skin Air Handling Units
Vertical Air Handling Units are designed to occupy lesser floor space than the horizontal units. These units are
preferred when floor space is a constraint. They are available in 10 models with airflow ranging from 3500 CMH
to 30280 CMH and an external static pressure at 12 mm and 20 mm. These are predominantly used for applications
where multiple units are required to aircondition a floor constrained by ceiling heights; duct sizing,
floor space etc.
10
730
780
830
980
830
980
980
1041
1132
1132
DVW-4-050
DVW-4-070
DVW-4-100
DVW-4-140
DVW-4-170
DVW-4-200
DVW-4-250
DVW-4-270
DVW-4-300
mm
3466
3164
2932
2932
2728
2220
1763
1591
1388
1032
mm
2372
2372
2244
2009
2009
1892
1852
1525
1349
1283
mm
LENGTH WIDTH HEIGHT
DVW-4-035
AHU
MODEL
3048
2794
2642
2642
2438
1930
1473
1321
1118
762
mm
FL
1080
1080
1016
826
762
762
762
572
508
508
mm
FH
Coil Details
3.29
3.02
2.68
2.18
1.86
1.47
1.12
0.75
0.57
0.39
Sq.m
Coil
Area
Floor Mounted Vertical Double Skin Air Handling Unit
17708
16233
14444
11736
10000
7917
6042
4063
3056
2083
CFM
30104
27595
24556
19951
17000
13458
10271
6906
5194
3542
CMH
Air Qty.
557*478 - 1#
471*404 - 1#
395*341 - 1#
331*289 - 1#
H-mm
W-mm X
Fan
FDA 500C2M
FDA 500C2M
FDA 450C2M
KAT 18/18S2L
638*638 - 2#
638*638 - 2#
568*568 - 2 #
557*478 - 2#
KAT 18/13S2L 430*478 - 2 #
KAT 15/15S2L 471*404 - 2 #
KAT 18/18SL
KAT 15/15SL
KAT 12/12SL
KAT 10/10SL
Dia. in
Fan Model
Opening
Velocity
10.27
9.42
10.57
10.41
11.49
9.82
10.72
10.08
10.71
10.28
M/Sec
Fan
Outlet
7.5
5.5
5.5
5.5
3.7
3.7
2.2
1.5
1.1
0.75
ESP
7.5
7.5
7.5
5.5
5.5
3.7
3.7
2.2
1.5
1.1
ESP
12 mm 20 mm
Motor kW
850
750
670
590
560
470
395
330
225
190
Kg.
950
815
745
650
610
520
435
360
245
205
Kg.
With 4 RD With 6 RD
Coil
Coil
Operating Wt.
(Approx.)
USER'S MANUAL
11
12
110
120
DVW - 4 - 300 17708 30080
600
W
600
H
400
W
400
H
600
W
500
H
500
W
500
10
DVW - 270
DVW - 300
DVW - 200
DVW - 250
DVW - 170
500
600
DVW - 140
600
2 1/2
2 1/2
2 1/2
1 1/2
1 1/4
1 1/4
Inch
SIZE
DVW - 100
DVW - 070
DVW - 050
DVW - 035
500
600
2 5/8
2 5/8
2 5/8
2 1/8
2 1/8
2 1/8
1 5/8
1 3/8
1 3/8
1 1/8
Inch
35.42 CDW-12-A-4-H-B-34-L/R-120-L
32.47 CDW-12-A-4-H-B-34-L/R-110-L
28.89 CDW-12-A-4-H-B-32-L/R-104-L
MS
6 Rows Deep
SIZE
COIL NOMENCLATURE
400
W
400
2
H
500
35.5
32.3
29.1
23.3
20.7
17.2
12.9
9.0
6.5
4.3
FT
Area
FILTER
CDW-12-A-6-H-B-34-L/R-120-L
CDW-12-A-6-H-B-34-L/R-110-L
CDW-12-A-6-H-B-32-L/R-104-L
CDW-12-A-6-H-B-26-L/R-104-L
CDW-12-A-6-H-B-24-L/R-96-L
CDW-12-A-6-H-C-24-L/R-76-L
CDW-12-A-6-H-C-24-L/R-58-L
CDW-12-A-6-H-C-18-L/R-52-L
CDW-12-A-6-H-C-16-L/R-44-L
CDW-12-A-6-H-D-16-L/R-30-L
HEADER CONNECTOR
MODEL
CDW-12-A-4-H-B-24-L/R-96-L
CDW-12-A-4-H-C-24-L/R-76-L
CDW-12-A-4-H-C-24-L/R-58-L
CDW-12-A-4-H-C-18-L/R-52-L
CDW-12-A-4-H-D-16-L/R-44-L
CDW-12-A-4-H-D-16-L/R-30-L
23.47 CDW-12-A-4-H-B-26-L/R-104-L
20.00
15.83
12.08
8.13
6.11
4.17
4 Rows Deep
COIL NOMENCLATURE
COPPER
FLAT FILTER SIZE (48mm THK.)
34
34
32
26
24
24
24
18
16
16
FT
AREA
COIL
AHU
Frontal Flat Filter Sizes
104
DVW - 4 - 270 16233 27574
76
58
13448
10263
DVW - 4 - 250 14444 24536
7917
DVW - 4 - 140
52
44
96
6042
DVW - 4 - 100
6901
5190
104
4063
DVW - 4 - 070
30
Inch
High
Length
DVW - 4 - 200 11736 19936
3056
DVW - 4 - 050
3539
CMH
Tube
Fin
DVW - 4 - 170 10000 16987
2083
CFM
AIR QTY.
DVW - 4 - 035
AHU MODEL
Coil Details
Vertical Double Skin Air Handling Unit
2 5/8
2 5/8
2 5/8
2 1/8
2 1/8
2 1/8
1 5/8
1 3/8
1 3/8
1 1/8
Inch
SIZE
HEADER
COPPER
2 1/2
2 1/2
2 1/2
1 1/2
1 1/4
1 1/4
Inch
SIZE
CONNECTOR
MS
USER'S MANUAL
Features
Ceiling Suspended Units
These units as the name suggests should be suspended from the ceiling thus requiring no floor space. These
units are ideal for commercial application where floor space is at a premium. As they are compact and can be
tucked away above the false ceiling, they find a place inside the conditioned area itself. Thereby reducing installation
costs and also remains unobtrusive giving flexibility to the design of the interior. Panels are fixed to the framework
by wedges thus avoiding usage of screws. They are available in 18 models with air quantity ranging from 1770
CMH to 13568 CMH and an external static pressure range of 12 mm and 20 mm.
The three models DCWSL-035,DCWSL-050 & DCWSL-070 are available in both direct driven with 3 speed single
phase motor or belt driven with 3 phase motor and the other AHUs are available in belt driven models only.
13
14
556
556
556
662
662
810
810
810
810
810
810
1238
1238
1743
1743
DCW4SL-027-B 908
DCW4SL-035-B 908
DCW4SL-042-B 948
DCW4SL-050-B 948
DCW4SL-060-B 1048 2200
DCW4SL-070-B 1048 2200
DCW4SL-078-B 1048 2130
DCW4SL-085-B 1048 2130
DCW4SL-093-B 1099 2097
DCW4SL-100-B 1099 2097
DCW4SL-110-B 1149 2333
DCW4SL-118-B 1149 2333
DCW4SL-127-B 1149 2638
DCW4SL-135-B 1149 2638
mm
556
556
556
556
mm
784
mm
DCW4SL-017-B 908
AHU Model
AHU Overall
Dimensions
(b) Belt Driven Type
2337
2184
2032
1880
1727
1778
1829
1676
1930
1727
1473
1219
965
762
508
mm
FL
0.735
0.561
0.368
Sq. Mt
Coil
Area
3958
3021
1979
CFM
635
635
635
635
635
572
508
508
381
381
381
381
381
381
381
mm
FH
1.484
1.367
1.290
1.194
1.097
1.016
0.929
0.852
0.735
0.658
0.561
0.465
0.368
0.290
0.194
Sq. Mt
Coil
Area
7986
7465
6944
6424
5903
5469
5000
4583
3958
3542
3021
2500
1979
1563
1042
CFM
13568
12683
11798
10913
10035
9297
8500
7791
6729
6021
5135
4250
3362
2655
1770
CMH
Air Quantity
6729
5135
3365
CMH
Air Quantity
Standard Coil Size
1930 381
DCW4SL-070-D 1048 2200 556
381
965
1473 381
mm
FH
DCW4SL-050-D 948 1743 556
mm
mm
mm mm
FL
Standard Coil Size
DCW4SL-035-D 908 1238 556
AHU Model
AHU Overall
Dimensions
(Fan, Coil,
Prefilter)
(a) Direct Driven Type
Fan Model
395 * 341 2 #
395 * 341 2 #
309 * 521 2 #
309 * 521 2 #
331 * 289 2 #
265 * 289 2 #
265 * 289 2 #
232 * 262 2 #
331 * 289 - 1#
265 * 289 - 1#
232 * 262 - 1#
W-mm * H-mm
Fan Opening
KAT 15-15 S2L 471 * 404 2 #
KAT 15-15 S2L 471 * 404 2 #
KAT 15-11 S2L 373 * 404 2 #
KAT 15-11 S2L 373 * 404 2 #
KAT12-12 S2L
KAT12-12 S2L
KAT12-9 S2L
KAT12-9 S2L
KAT10-10 S2L
KAT10-8 S2L
KAT10-8 S2L
KAT 9 - 7 S2L
KAT10-10 SL
KAT10-8 SL
KAT 9 - 7 SL
Kruger
331 * 289 - 1#
265 * 289 - 1#
331 * 289 - 1#
W-mm * H-mm
Fan Opening
Fan & Motor Details
KDD10-10 S2L
KDD10-08 S2L
KDD10-10 SL
Kruger
Fan Model
9.91
9.26
10.88
10.06
10.35
9.59
11.20
10.27
9.77
10.92
9.31
9.71
9.77
9.64
8.09
m/s
Fan
Outlet
Velocity
9.77
9.31
9.77
m/s
3.7
3.7
3.7
2.2
2.2
2.2
2.2
2.2
1.5
1.5
1.1
1.1
0.75
0.55
0.55
kW
Motor
Power
3.7
3.7
3.7
3.7
3.7
3.7
2.2
2.2
2.2
1.5
1.5
1.1
1.1
0.75
0.55
kW
Motor
Power
20mm
ESP
0.55
0.55
0.55
Motor Kw.
12 mm ESP
12mm
ESP
Fan Outlet
Velocity
Fan & Motor Details
Size
610 * 610
610 * 610
610 * 610
3
1
610 * 610
305 * 610
305 * 610
610 * 610
610 * 610
1
3
500 * 500
500 * 500
400 * 500
Qty
400 * 500
500 * 400
500 * 400
500 * 400
500 * 400
500 * 400
500 * 400
600 * 400
-mm * H-mm
Size
Pre Filter
(50mm thick.)
500 * 400
500 * 400
500 * 400
Operating Wt.
(Approx.)
290
195
165
Kg.
310
215
180
Kg.
With 4 RD With 4 RD
Coil
Coil
Operating Wt.
450
440
425
415
395
385
360
345
330
320
225
215
190
175
150
Kg.
49 5
475
460
445
435
425
400
380
360
348
245
230
205
195
170
Kg.
With 4 RD With 4 RD
Coil
Coil
Qty
Pre Filter
(50mm thick.)
W-mm * H-mm
Double Skin Ceiling Suspended AHU-Technical Specification
1042
1563
1979
2500
3021
3542
3958
4583
5000
5469
5903
6424
6944
7465
7986
DCW-027
DCW-035
DCW-042
DCW-050
DCW-060
DCW-070
DCW-078
DCW-085
DCW-093
DCW-100
DCW-110
DCW-118
DCW-127
DCW-135
CFM
13576
12691
11805
10921
10035
9297
8500
7791
6729
6021
5136
4250
3364
2657
1771
CMH
Air Qty
DCW-017
AHU Model
92
86
80
74
68
70
72
66
76
68
58
48
38
30
20
Inch
Fin
Length
20
20
20
20
20
18
16
16
12
12
12
12
12
12
12
Tube
High
50.17
47.22
44.27
41.32
38.37
35.42
32.47
28.89
23.47
20.00
15.83
12.08
8.13
6.11
4.17
FT
Coil
Area
CDW-12-A-4-H-B-20-L/R-92-L
CDW-12-A-4-H-B-20-L/R-86-L
CDW-12-A-4-H-B-20-L/R-80-L
CDW-12-A-4-H-B-20-L/R-74-L
CDW-12-A-4-H-B-20-L/R-68-L
CDW-12-A-4-H-B-18-L/R-70-L
CDW-12-A-4-H-B-16-L/R-72-L
CDW-12-A-4-H-B-16-L/R-66-L
CDW-12-A-4-H-B-12-L/R-76-L
CDW-12-A-4-H-B-12-L/R-68-L
CDW-12-A-4-H-C-12-L/R-58-L
CDW-12-A-4-H-C-12-L/R-48-L
CDW-12-A-4-H-D-12-L/R-38-L
CDW-12-A-4-H-D-12-L/R-30-L
CDW-12-A-4-H-D-12-L/R-20-L
4 Rows Deep
Coil Nomenclature
2 1/8
2 1/8
2 1/8
2 1/8
1 5/8
1 5/8
1 5/8
1 5/8
1 3/8
1 3/8
1 1/8
1 1/8
1 1/8
1 1/8
1 1/8
Inch
Copper
Header
Size
1 1/2
1 1/2
1 1/2
1 1/2
1 1/4
1 1/4
Inch
MS
Connector
Size
Double Skin Ceiling Suspended AHU - Coil Details
CDW-12-A-6-H-B-20-L/R-92-L
CDW-12-A-6-H-B-20-L/R-86-L
CDW-12-A-6-H -B-20-L/R-80-L
CDW-12-A-6C-H-B-20-L/R-74-L
CDW-12-CA-6-H-B-20-L/R-68-L
CDW-1 2-A-6-H-B-18-L/R-70-L
CDW-12-A-6-H-B-16-L/R-72-L
CDW-12-A-6-H-B-16-L/R-66-L
CDW-12-A-6-H-B-12-L/R-76-L
CDW-12-A-6-H-B-12-L/R-68-L
CDW-12-A-6-H-C-12-L/R-58-L
CDW-12-A-6-H-C-12-L/R-48-L
CDW-12-A-6-H-D-12-L/R-38-L
CDW-12-A-6-H-D-12-L/R-30-L
CDW-12-A-6-H-D-12-L/R-20-L
6 Rows Deep
Coil Nomenclature
2 1/8
2 1/8
2 1/8
2 1/8
1 5/8
1 5/8
1 5/8
1 5/8
1 5/8
1 5/8
1 1/8
1 1/8
1 1/8
1 1/8
1 1/8
Inch
Copper
Header
Size
1 1/2
1 1/2
1 1/2
1 1/2
1 1/2
1 1/2
Inch
MS
Conenctor
Size
USER'S MANUAL
15
CDW / CDX Coils: Nomenclature

1. CDW Water Cooling Coils:
CDW
12
24
94
Comfort Water Cooling Coil

Fins per Inch, 12 FPI
Fins Material, A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H: Horizontal
Circuiting (Tubes per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand, R: Right, L: Left
Finned Length (FL), 26 to 114
L: Loose
Note: Field to specify (a) Circuit type: B. C. D; (b) Hand-off connection: LHS, RHS.
Coil Specifications: OD Copper tube, Tube thinkness 0.36mm, Fin thickness: 0.12mm Aluminium fins.
16
USER'S MANUAL
2. CDX Direct Expansion Cooling Coils:
CDX
12
24
94
0156
40
12
Comfort Direct Exp.

Fins Material A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Circuiting (Tuber per Circuit), B=4, C=6, D=8
Hand. R: Right, L: Left
Finned Length (FL), 26" to 114"
L: Loose
Total Coil Load in MBH,
1 MBH = 1000 BTU/HR
Suction Temp., Deg. F
Tubes per Circuit, B=4, C=6, D=8
No. of Circuits
Note: Field to specify (a) Circuit type: B. C. D; (b) Hand-off connection: LHS, RHS.
Coil Specifications: OD Copper tube, Tube thinkness: 0.36mm, Fin thickness: 0.12mm Aluminium fins.
17
Double Skin Horizontal Floor Mounted ('E' Family)

Design:
Computerised selection
AHU selection software is used for optimal model selection for customised needs. The selection software provides
the following information:
Overall dimensional details
Technical Data Sheet
Sections selected
GA Drawing
Details of Individual sections
Costing Sheet
Casing
Rigid framework, comprising of externally chamfered extruded aluminum anodised profiles, with fibre glass corner
joints.
Double skin sandwiched panels :

Inner Skin
: 0.5mm plain galvanized sheet confirming to IS 277.
Sheet options
: 0.6mm GP, 0.8mm GP, 1.0mm GP, 1.2mm GP, 0.9AI, 1.2mm Al,
0.6mm SS(304), 0.8mm SS(304).
Outer Skin
: 0.5mm pre-painted galvanised sheet.
Sheet options
: 0.6mm PP, 0.8mm PP, 1.0mm PP, 0.9mm AI, 1.2mm Al, 0.6mm SS-304,
0.8mm SS-304.
Panels are pressure injected with polyurethane foam, using CFC-free R-141b blowing agent. High and uniform
PUF density of 38+ 2Kg/m3 provide better thermal insulation K factor (not exceeding 0.02 Watt / MC) and
sound attenuation properties. The following options can be selected based on customer requirement.
Option 1: Panels of 24+ 1mm thickness with standard aluminum extrusions and fiberglass corner joints.
Option 2: Panels of 46+ 1mm thickness with internally coved thermal break aluminum extrusions and
fiberglass corner joints. Recommended for total static pressure above 85 mm and these AHUs are suitable
for outdoor installation.
Panels are fixed to frame with tapered wedges inserted in aluminum extrusions. The gaskets have stable
thermal conductivity and less water vapour permeability.
Fan and motor are mounted on aluminium extruded slide rail base frame. It is isolated from main casing by
using vibration isolators (using 15mm nominal deflection). To arrest vibration, fan outlet is connected to the
AHU casing using fire and moisture resistant canvas.
Hinged service door in fan section provides easy access to fan and motor. View port is provided on fan door
panel to help to monitor fan and motor status. Marine lamp provides easy visibility. Door limit switch
automatically trips the motor when the door is opened and hence stop the blower.
Drain pan with differential slope assures quick and complete water drainage ensuring high Indoor Air Quality
(IAQ). Drain Pan is 80mm deep and fabricated from 0.8 mm thick GI Powder Coated and optional 1.25mm
powder coated or corrosion resistant SS-304 stainless steel is available. The drain pan is insulated for thermal
protection with 5mm thick closed cell elastomeric insulation to avoid surface condensation.
AHUs with stack coils have additional intermediate G.I powder coated / stainless steel drain pan to collect
the condensate of top coil and drain through PVC drop tubes to the main drain pan without flooding the lower
coil.
18
USER'S MANUAL
AHU is supplied with factory fitted GI, powder coated, opposed blade volume control damper to facilitate
field balancing.
Aluminium die cast powder coated hinges provide adequate strength to the door. Nylon handles can be
operated from both inside and outside the casing and are user friendly.
Cooling Coils
Free flow fin configuration formed by mild ripples and die formed channels provide excellent heat transfer
capability with low air pressure drop. Mechanical expansion of copper tube with aluminium fins assures tight
bonding, providing optimum heat transfer. Coils are complete with copper headers.
Water or Direct Expansion coils can be selected based on requirement. Water coils are self draining and vented
type. Design working pressure is 250 psig. at 300F.
The following options of sectional length can be selected based on requirement:
Coil Section up to 6 Row Deep
Coil Section up to 8 Row Deep
Cooling Coil 6 Row Deep and Heating Coil 2 Row Deep
Cooling Coil 8 Row Deep and Heating Coil 2 Row Deep
Fans
Fans are imported, AMCA certified, energy efficient, with double inlet, double width, forward or backward curved
impeller. All wheels are statically and dynamically balanced. Fan bearings are self-aligning, pillow block or flanged
type regreasable ball bearings. The scroll and impeller are made of galvanised steel sheet. The fan is V-belt
driven through a 3 phase, 415V6%, 50 Hz AC, squirrel cage, TEFC induction, 4 Pole, IP55, Class F motor.
AHUs with static pressure requirement of more than 85mm are suggested with backward curved impeller.
Pre Filters (50mm thick)

Pre Filters are pleated to provide more filtration area. The filters are of the cassette type. The filter media are of
the synthetic non-woven type, supported with aluminium and HDPE mesh and generally conforming to EU-3 of
EN-779 specifications. Filter efficiency is 90% down to 10 micron. Filters are provided with handles for easy
removal.
Mixing Box / Inlet Section (Optional)

Section is designed for interconnecting return air and fresh air. The following options can be selected based on
requirement:
Mixing Box section with one Return Air Damper and Pre Filters
Mixing Box section with one Fresh Air Damper & Pre Filters.
Mixing Box section with Return and Fresh Air Damper and Pre Filters
Mixing sections are fitted with parallel or opposed blade multi-leaf dampers suitable for manual or motorised
operations. Select aluminium damper only for requirement with motorised modulating motor operation.
19
Fine / Bag Filter Section (Optional)

Section is designed for 300/500/600mm deep Fine filters or Bag filter with 25 mm flange.
The filters are arranged vertically in the specially designed heavy-duty galvanized sheet steel frame to avoid air
bypass and are removable from front. Filters are mounted on frame with positive clamping arrangement. Filter
section is provided with access door panel, with aluminum die-cast powder coated heavy duty hinges and nylon
handles with positive locking. The handle can be operated from both ends for ease in serviceability.
HEPA Filter Section (Optional)

Section is designed for 300mm deep HEPA Filters with 25 mm flange.
The filters are arranged vertically in the specially designed heavy-duty galvanised sheet steel frame to avoid air
bypass and are removable from front. Filters are mounted on frame with positive clamping arrangement. HEPA
Filter section is provided with access door panel, with aluminum die-cast powder coated heavy duty hinges and
nylon handles with positive locking. The handle can be operated from both ends for ease in serviceability. HEPA
Filter should be selected only after Fine or Bag filters.
Combination Filter Section (Optional)

Section is designed for combination of 50mm thick Pre Filters mounted together with Fine / Bag Filters. The filters
are arranged vertically in the heavy duty galvanised sheet steel frame and removable from front. Filters are
mounted on frame with positive clamping arrangement. Fine / Bag filters can be removed only after the removal
of prefilter. All filters are also available in Aluminium flange for phama or clean room application.
Face and Bypass Damper Section (Optional)

Standard face and bypass dampers are of opposed blade type. Face damper is at the bottom in front of the coil,
and bypass damper is on the top. Two dampers are interlocked and provide a single control point. The opening
size in the frame for mounting the Face damper will be equal to maximum size of coil
Select aluminium damper only for requirement with motorised operation with modulating motor. Motorised
actuators are of direct mounting type. It could be two position (on/off) or modulating (input signal 0-10V DC or
4-20mA).
Droplet Eliminator Section (Optional)

To avoid condensate or spray of water carryover into the fan section, suggest use the following droplet eliminator
after the coil or spray section:
2 Pass GI / PVC Droplet Eliminator
4 Pass GI / PVC Droplet Eliminator
Humidification Section (Optional)

Celdek type humidification section is provided in AHU for cooling and humidification purpose, this is required in
places where the temperature is quite high with low humidity.
In humidification section 175 mm high sump is used to store the water and this water is circulated and spread
over the cellulose Pad (Celdek Pad) with the help of Pump and piping arrangement.
The cellulose pad is designed at 500 FPM (2.54m/sec) of Air velocity and it is available in 6" (150 mm),
8" (200 mm) of thickness.
20
USER'S MANUAL
8" Cellulose pad should be used to get the saturation efficiency of about 90%.
The droplet eliminator of 4 pass must be provided after the humidification section to avoid any water carry over
in the supply air.
Heater Section
Heater section with appropriate capacity of heater should be selected to maintain the RH.
These heaters can be provided in number of stages and banks as per the requirement.
Heat Recovery Wheel

Heat Recovery wheel is used in applications where we want to utilize the heating or cooling of the supply air
without mixing with the fresh air.
In other words heat recovery wheels are desirable where we want the heat transfer from supply air to the fresh air
without the mass transfer.
It is used in fresh air application in double tier arrangement.
Heat recovery wheel is placed before the coil and as it recover some quantity of heat (Cooling) from the supply
air, it helps reducing the load on the coil and hence lesser capacity of chiller/condensing unit is required.
The effectiveness of the heat recovery wheel is about 75 80%.
Heat Pipe
Run around type (Horse shoe type) or vertical heat pipe can be provided in our AHUs.
Run around type Heat Pipe has Pre cooling and Re Heating coils, connected through the refrigerant piping.
The hot air interact with the Pre cooling side of the coil and get cooled, the refrigerant inside the coil get evaporated
and get accommodated in the reheating coil.
This pre cooling helps in reducing the load on the main coil and the air after passing through the main coil gets
further cooled and is with high RH.
The Re heating side of the coil exchanges the heat with this cooled and high RH Air, and gets converted into
liquid form.
This liquid state refrigerant due to gravity gets accumulated in the pre cooling coil.
The Air After passing through the Re-Heating Coil gets heated to maintain the desirable temp. 22-24C in the
room with a moderate RH of 50-60% in the room, which is desirable.
The effectiveness of the heat Pipe is about 45 65 %.
The vertical type of heat pipe is used in two tier arrangement, which recovers the sensible heat from return air.
Variable Pitch pulley

Variable Pitch Pulley can be provided in AHUs, which can be set as per the Air Quantity requirement.
Flat belt
Flat belt with pulley arrangement cab be provided on demand.
Damper Actuator
Damper Actuator can be provided to modulate the dampers of the AHUs.
21
VFD
Variable frequency drive can be provided with AHU, which helps in maintaining varying air flow by changing the
frequency and thereby Rpm of the motor to maintain the desired conditions. HVAC VFD with inbuilt basic controls
can also be provided.
UV emitter
UV emitter is used to improve the indoor Air Quality.
It can be mounted on the coil and hence does not require any extra space to mount.
Activated carbon filter

Activated carbon filter is used to remove the odor from the Air and can be provided in our AHU.
Empty Section
Sections with different lengths are available to suit any specific requirement.
Base Channel
Entire unit is completely supported by a full-perimeter base rail channel. The base rail is constructed of
2mm thick galvanised sheet steel and has intermediate cross member for unit support.
Unit Assembly
Units are despatched ex-factory upto E-500 in Top and Bottom assembled condition, and above that in dismantled
condition. The assembly of units will be carried out at site.
Factory Test
Each coil is factory tested and checked for leaks at 325 Psig (pneumatic) under water.
Performance Standards are:
In accordance to
Fans
- AMCA 210
Coils
- ARI 410
Motors - IS-325
Filter
- BS-6540 / ASHRAE 52 - 76
Note: E-Family AHU details can be obtained through E-Family AHU Selection Software.
22
USER'S MANUAL
YDW / YDX Coils: Nomenclature

1. YDW Water Cooling Coils:
YDW
12
24
94
Water Cooling Coil

Fin Material A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
L: Loose
Note: Field to specify (a) Circuits1/2" Copper) C. D; (b) Hand-off connection: LHS, RHS (viewing from air entering side)
Coil Specifications : OD Copper tube of thickness 0.41 mm with 0.14mm Aluminium fins.
Coils are OD Copper tube of thickness 0.5 mm with 0.15mm Aluminium fins are available as an option.
23
2. YDX Direct Cooling Coils:

YDX
12
24
94
0156
40
Direct Exp.
Fin Material, A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H : Horizontal
L: Loose
Total Coil Load in MBH,
1 MBH = 1000 BTU/HR
Suction Temp., Deg. F
Tubes per Circuit, B=4, C=6, D=8
No. of Circuits
Note: Field to specify (a) Tube per circuit; (b) Hand-off connection: LHS, RHS.
Coil Specifications: OD Copper Tube of thickness 0.41mm with 0.14mm Aluminium fins.
Coils of OD Copper Tube of thickness 0.5mm with 0.15mm Aluminium fins are available as an option.
24
12
USER'S MANUAL
Transportation Storage
General
This manual is a complete guide for the Installation, Operation and Maintenance of Blue Star's Double Skin Air
Handling Units.
Proper installation, operation and maintenance are essential to optimise use of the AHU. The services of a qualified
technician from a reputed service company must therefore be employed through a suitable contract to install the
AHU.
Transportation & Handling

The Air Handling Units are inspected prior to despatch to ensure that the coil fins, casing panels, exteriors, fan
scroll and impeller are in good condition, cross-checked against items ordered, then packed and carefully loaded.
Material Receipt
Carefully inspect all material immediately upon delivery. If any damage is noticed, note the same and inform Factory
by telephone, fax or email within one week of receiving the material. Also fill up the Field Feedback Card which
accompanies the despatch documents and forward to Factory.
Storage
1. Protect the units from dust and dirt.
2. Do not store internal parts such as fans, motors, cooling coils, etc., in the open. If external parts are stored
in the open, ensure that they are well protected against the weather.
3. Do not place sections on top of each another.
4. Do not walk or place weight on top of the units.
5. Do not lean any materials on the units that can damage them, such as panels, aluminum profiles or other
external components.
6. Do not store any kind of materials inside sections.
7. Keep the units away from all passageways.
8. Protect protruding parts, coil connection, damper shafts, etc.
9. Place wooden wedges between the units and the ground.
10. Motors must not be stored in damp areas.
11. Filters must be left within packing cartons until ready for installation.
12. Protect fans from debris and dust.
25
Rigging Instruction
Proper rigging and handling of the equipment is mandatory during unloading and leading the AHU into position.
Care must be taken to keep the unit upright during rigging. Avoid unnecessary jarring or rough handling.
Proper hoisting straps should be used when rigging (nylon flat rope). It is also mandatory that an experienced
and reliable rigger be selected to handle unloading and final placement of the equipment. The rigger must be
advised that the unit contains internal components that require to be kept in an upright position. Care must be
exercised to avoid twisting of the equipment.
When the equipment is installed in its position, check the following:

1. Check all choke seams and air seals (below fan, motor etc.).
2. Check all door latches and re-adjust if necessary to maintain a good tight seal.
3. Fill up the Field Commissioning Report which accompanies the despatch documents and forward to Factory
upon commissioning of the AHU.
26
USER'S MANUAL
Packing List 25mm STANDARD-SKD Condition

CFM :
AHU Model
AHU Tag No.
Fan Model
Discharge Location
Coil Connection
SP : 50
630 CM
AHU Overall Dimensions (W * H * L) :

ICO No.
Batch Quantity
Sr.
No.
Item Description
1
U.M.
CASE
No.
SIZE
Q/S
Puf Panels
FAN + COIL SECTION
1
4
TOP /BOTTOM ASSEMBLY

Panel TOP (CUTOUT)
No.
4 -A
Panel TOP
No.
4 -B
Panel TOP
No.
Panel BOT
No.
5 - A
Panel BOT
No.
6 - B
Aluminum Extrusion Screwless - Length
No.
Aluminum Extrusion Screwless - Width
No.
Aluminum Extrusion Screwless B Type - Width
No.
8 - A
Aluminum Wedge
No.
8 - B
Aluminum Wedge
No.
8 - C
Aluminum Wedge
No.
8 - E
Aluminum Wedge
No.
19
Blower Sssly
19 - A
Spring isolator chanel
No.
19 - B
C - Fabrication
No.
19 - C
Motor mount
No.
19 - D
M - 12 Nut plate - 1
No.
19 - E
M - 12 Nut plate - 2
No.
20
CASE - 1
(Assembled
in Top / Bottom
Assembly)
Base Assly
20 - A
Base length - RH
No.
20 - B
Base length - LH
No.
20 - C
Base Width
No.
27
Sr.
No.
Item Description
U.M.
20 - D
Base Center
No.
20 - E
Base Corner
No.
25
Drain Pan
No.
22
Discharge flange Assly (Welded)
22 - A
CASE
No.
Discharge flange No.
17
Antivibrant Flexible Canvas Connection
No.
21
Coil Support No.
33
Motor Base Plate (50mm S.P)
No.
34
Spring Isolators - Fan Side Mounting
No.
35
Spring Isolators - Near to Motor
Set.
36
Spring Isolators - Away From Motor
No.
Back, LH and RH panels
Case 2
Panel LH - DOORNo.
27
Hinges ( Assembled with Door)
No.
37
BLUE STAR Logo (FIXED ON DOOR PANEL)
No.
1 - A
Panel LH
No.
1 - B
Panel LH
No.
Panel BACK
No.
2 - A
Panel BACK
No.
Panel RH
No.
3 - A
Panel RH
No.
3 - B
Panel RH
No.
6 - A
Aluminum Extrusion Screwless - Height
No.
7 - A
Aluminum Extrusion Screwless B Type - Height
No.
8 - A
Aluminum Wedge
No.
8 - B
Aluminum Wedge
No.
8 - C
Aluminum Wedge
No.
8 - D
Aluminum Wedge
No.
8 - F
Aluminum Wedge
No.
Loose Items
9
Blower
No.
12 - A
Blower Pulley (50mm S.P)
No.
10 - A
Coil
No.
Rubber Bush / Washer For Coil Header fixed on header.
Set.
11 - A
Motor (50mm S.P)
No.
13 - A
Motor Pulley (50mm S.P)
No.
42
28
case 3
case 4
case 4
case 5
case 5
SIZE
Q/S
USER'S MANUAL
Sr.
No.
Item Description
U.M.
CASE
No.
15
Damper : SA
No.
case 6
16
Pre Filter :
No.
case 7
16 - A
Pre Filter :
No.
SIZE
Q/S
Fabrication List
18
case 8
Filter frame Assly (Welded)

size
23
Coil Frame Assly
23 - A
Coil frame - TOP
No.
23 - B
Coil frame - LH
No.
23 - C
Coil frame - RH
No.
23 - D
Coil frame - BOT
No.
24
case 9
Spool Assly
24 - A
No.
24 - B
No.
Hardwares
26
Plastic Corner
No.
28
Handle
No.
29
Marine Light
No.
30
Limit Switch
No.
31
Hardware Set.
Set.
38
Door Switch Bracket.
No.
39
PTTJoint (25mm Standard) (FIXED WITH EXTRUSION)
No.
Belt (50mm S.P) - in hardware box
No.
40
Stickers
Set.
41
Rubber Bush / Washer For Cable Entry
Set.
14 - A
case 10
29
Packing List 25mm STANDARD-CKD Condition

AHU Model
AHU Tag No.
Fan Model
Discharge Location
Coil Connection
CFM
SP : 50
FDA
1000 CM
UPBLAST
AHU Overall Dimensions (W * H * L) :

ICO No.
Batch Quantity
Sr.
No.
Item Description
U.M.
Puf Panels
FAN + COIL SECTION
1
Panel LH
No.
Panel LH - DOOR
No.
Panel BACK
No.
2 - A
Panel BACK
No.
Panel RH
No.
Panel TOP
No.
4 -A
Panel TOP (CUTOUT)
No.
4 -B
Panel TOP (CUTOUT)
No.
Panel BOT
No.
1 - A
Aluminium Extrusions
30
Aluminum Extrusion Screwless - Width
No.
6 - A
Aluminum Extrusion Screwless - Height
No.
6 - B
Aluminum Extrusion Screwless - Length
No.
Aluminum Extrusion Screwless B' Type - Width
No.
7 - A
No.
7 - B
No.
7 - C
Aluminum Extrusion Screwless B' Type - Height
No.
8 - A
Aluminum Wedge
No.
8 - B
Aluminum Wedge
No.
8 - C
Aluminum Wedge
No.
8 - D
Aluminum Wedge
No.
8 - E
Aluminum Wedge
No.
8 - F
Aluminum Wedge
No.
8 - G
Aluminum Wedge
No.
Case
No.
Size
Q/S
USER'S MANUAL
Sr.
No.
Item Description
U.M.
Case
No.
Size
Q/S
Loose Items
9
Blower
No.
11
Coil
No.
11 - A
Coil
No.
12- A
Motor (50mm S.P)
No.
13 - A
Blower Pulley (50mm S.P)
No.
14 - A
Motor Pulley (50mm S.P)
No.
15 - A
Belt (50mm S.P)
No.
16
Damper : SA
No.
17
Pre Filter :
No.
17 - A
Pre Filter :
No.
Antivibrant Flexible Canvas Connection .
No.
18
Fabrication List
19
Filter frame Assly (Welded)
19 - A
Filter frame top
No.
19 - B
Filter frame side
No.
19 - C
Filter center support
No.
19 - D
Spring back down
No.
19 - E
Spring back up
No.
20
Blower Sssly
20 - A
Spring isolator chanel
No.
20 - B
C - Fabrication
No.
20 - C
Motor mount
No.
20 - D
M - 12 Nut plate-1
No.
20 - E
M - 12 Nut plate-2
No.
21
Base Assly
21 - A
Base length - RH
No.
21 - B
Base length - LH
No.
21 - C
Base Width
No.
21 - D
Base center
No.
21 - E
Base center - 2
No.
21 - F
Base Corner
No.
22
Coil Support
No.
23
Discharge flange Assly (Welded)
23 - A
Discharge flange
No.
31
Sr.
No.
Item Description
U.M.
24
Coil Frame Assly
24 - A
Coil frame - TOP
No.
24 - B
Coil frame - LH
No.
24 - C
Coil frame - RH
No.
24 - D
Coil frame - BOT
No.
25
Intermediate coil support
No.
26
Spool Assly
26 - A
No.
26 - B
No.
Drain Pan
No.
27
Hardwares
28
Plastic Corner
No.
29
Hinges (Assembled with Door)
No.
30
Handle
No.
31
Marine Light
No.
32
Limit Switch
No.
33
Hardware Set
Set.
35
Motor Base Plate (50mm S.P)
No.
36
Spring Isolators - Fan Side Mounting .
No.
37
Spring Isolators - Near to Motor
Set.
38
Spring Isolators - Away From Motor
No.
39
BLUE STAR Logo (FIXED ON DOOR PANEL)
No.
40
Door Switch Bracket No.
41
PTT Joint (25mm Standard)(FIXED WITH EXTRUSION)
42
Stickers
43
Set.
44
Rubber Bush / Washer For Coil Header
Set.
34
Set.
(FIXED WITH COIL HEADER)
32
No.
Case
No.
Size
Q/S
USER'S MANUAL
Assembly Procedure of Double Skin

Horizontal Floor Mounted AHU
The Handling units models DHW - 035C to DHW - 500C are dispatched in SKD condition with Top and Bottom
panels assembled. The models DHW - 520C to DHW - 600 C are dispatched in CKD Condition.
A sample packing List for AHUs despatched in SKD and CKD Conditions are shown below:
Packing List 25mm STANDARD

(Screwless Construction)
AHU Model
AHU Tag No
DHW - 070
3750 CFM
Fan Model
FDA 355 CM
Air Flow
3750 CFM
Static Pressure
50 mm
RPM
1038
Discharge Location
Up blast (CCW 360)
AHU Overall Dimensions :
1370 (W) x 869 (H) x 1555 (L)
Customer Name
431-162-RVP-AGI-09
ICO No
431-162-RVP-AGI-09
Batch Quantity
Sr. No.
1
Item Description
U.M.
CASE No.
Size
Q / S
TOTAL QTY.
Puf Panels
1 .
Pre Flat Filter
2 .
Cooling Coil 6 Row
2 . 1
Panel : Left
460
784
2 . 2
Panel : Right
460
784
2 . 3
Panel : Top
460
1285
3 .
Fan Section
3 . 1
Panel : Top
460
1285
3 . 2
Panel : Top
460
1285
3 . 3
Panel : Bottom
460
1285
3 . 4
Panel : Bottom
460
1285
3 . 5
Panel : Back
620
784
3 . 6
Panel : Back
620
784
3 . 7
Panel : Access Door Right
460
784
3 . 8
Panel : Right
460
784
3 . 9
Panel : Left
460
784
3 . 10
Panel : Left
460
784
13
13
Total No. of Panels:
Aluminium Extrusions
Aluminium Extrusion A Type - Height
756
Aluminium Extrusion A Type - Width
1257
Aluminium Extrusion A Type - Length
1442
Aluminium Extrusion B Type
756.4
1257.4
624.4
181.4
Aluminium Wedges - TOP
463
1268
628.5
185.5
Aluminium Wedges - LEFT
463
Aluminium Wedges - LEFT
767
33
Aluminium Wedges - RIGHT
463
Aluminium Wedges - RIGHT
767
Aluminium Wedges - BOTTOM
463
Aluminium Wedges - BOTTOM
1268
Aluminium Wedges - BACK
623
Aluminium Wedges - BACK
767
Aluminium Wedges - For Frontal Flat Filter Frame(Height)
767
Aluminium Wedges - For Frontal Flat Filter Frame(Width)
1288
Aluminum Extrusion BAS-40C-Type Fan side
820
Aluminum Extrusion BAS-40C-Type Motor side
635
Sections
1
Pre Flat Filter

Prefilter: Box Type 48mm, Al Frame EU-3
(90% down to 10 micron)
Nos
610 (W) X 610 (H)
Frontal Flat Filter Frame
Set
1285(W) x 784(H)
Cooling Coil
Nos
YDW-12-A-6-H-C-22-L-40-L
Cooling Coil Frame
Nos
1299(W) x 798(H)
1240(W) x 415(L)
Cooling Coil 6 Row Section
Insulated Bottom Drain Pan (0.8 mm S.S-304) New Design
Nos
Drain Pan Deflector Plate
Nos
1235
Coil Support for Drain pan
Nos
1302
Rubber Bush / Washer For Coil Header
Nos
Fan Section
Fan
Nos
FDA 355CM
Motor
Nos
3HP, 4Pole
S.A. DAMPER ,GI(Standard)
Nos
452(W) x 452(H)
Blower Pulley
Nos
140mm PCD 30mm ID
Motor Pulley
Nos
100mm PCD 28mm ID
Belt (PACKED IN HARDWARE BOX)
Nos
1060 SPA (1)
Antivibrant flexible canvass connection
Nos
452(W)X452(L)
Motor Base Plate
Nos
3HP
T-Bolt
Nos
M10 X 20
12
12
Anti Vibration Isolater - As Shown in Fig. Point 1
Nos
RM 19. 100. B
Nos
RM 19. 100. R
Nos
RM 19. 100. R
Nos
RM 19. 100. B
Marine Light
Nos
Limit Switch
Nos
Polycarbonated Window
Nos
Spool for Vertical Discharge
Nos
Door Switch Bracket
Nos
Nos
Handle For Access Door
Nos
Hinges
Nos
BLUE STAR Logo .(FIXED ON DOOR PANEL)
Sets
452(W) x 452(L) x 29(H)
Spring Isolater Channel
Set
1301 (L) x 85 (W)
S.A. Flange
Nos
452 (W) x 452 (H) x 75
Channels
Channel, Base. (Width)
Nos
1244
Channel, Base. (Length)
Nos
1429
Channel, Base. (Centre)
Nos
1344
1
8
Hardwares
34
Plastic Corner (for 25mm)
Nos
GI Base (25mm)
Nos
Gasket :
PTT Joint (25mm Standard )(FIXED WITH EXTRUSION)
Roll
Nos
4
18
4
18
Hardware Set
Set
Stickers
Set
20 * 3 mm
USER'S MANUAL
Assembly the AHU

Base Channel Assembly
1. Assemble GI base channel and corner piece with M6x25 mm long bolt and nut with one plain and one spring
washer on each side.
2. Overall dimensions of the base channel frame should be 30 mm less in length and width than the length and
width of the AHU / AHU Module.
Diagonally, the base frame should not be out by more than 1 mm.
All the base corners must be fitted from the inside.
35
Top Panel Assembly

1. Refer panel arrangement drawing. Assemble A type extrusion with glass filled nylon corners to form a top
frame required for fixing top panel - Drill the hole of 4.2mm & Rivet it with 7/16"x1/2" long rivet.
2. Place the B type extrusion on the specified distance mentioned in the panel arrangement Drawing.
3. Place the panel as shown in the drawing and maintain equal gap of 2 3mm between frame and panel all
around.
4. Insert the taper lock wedge in to the groove of A type and B type extrusion to lock the panel with extrusion.
5. Rivet the B type extrusion on A type extrusion by using 3/16" x 1/2" long rivet from inside.
6. If the fan orientation in the AHU is upblast, then fix the canvas connection flange on the cut out of the panel.
Reverse the top panel and fix the canvas connection from inside on connection flange.
Taper lock wedge should be inserted inside the groove of the extrusion until
its step touches to extrusion.
36
USER'S MANUAL
Bottom Panels Assembly

1. Refer panel arrangement drawing .Assemble A type extrusion with glass filled nylon corners to form a bottom
frame required for fixing bottom panel .
2. Place the B type extrusion on the specified distance mentioned in the panel arrangement Drawing.
3. Place the panel as shown in the drawing and maintain equal gap of 2 3 mm between frame and panel all
around.
4. Insert the taper lock wedge in to the groove of A type and B type extrusion to lock the panel with extrusion.
Empty space left is for drain pan.
5. Rivet B type extrusion on A type extrusion by using 3/16" x 1/2" long rivets.
Taper lock wedge should be inserted inside the groove of the extrusion until
its step touches to extrusion.
37
Base Channel & Bottom Frame Assembly

1. Position the base channel frame on the bottom frame. Maintain equal distance from all sides.
2. After positioning the frame, fix it with self drilling and tapping screws of size 4.2 mm x 25 mm long.
3. Use battery operated screw driver / power screw driver with Philips head for fixing self drilling and tapping
screws.
4. Turn the assembly upside down.
Normally bottom panel frame is 25mm more in size from all the side than
GI base channel assembly.
38
USER'S MANUAL
Drain Pan Assembly

1. Position the drain pan in the space left by panels in the bottom frame. Drain nipple should be on the header
side.
2. Place the drain pan in position and rivet it to the main frame with rivets of size 3/16" x 1/2" long.
3. Place the coil channel on the top of the drain pan and fix it on A type extrusion with the help self drilling /
tapping screws.
4. Apply some silicon gel at the periphery / edges of drain pan to avoid leakage.
Ensure that the drain nipple side of the drain pan should be on the side of
header of the coil.
39
Rubber Mount /Spring Isolator Assembly

1. Refer packing list for the type of rubber mount / spring isolator to be used and position it accordingly. Each
type of rubber mount or spring isolator is having different load carrying capacity.
2. Fix the rubber mount / spring isolator on the isolator channel .Place C type channel used for blower and
motor mounting on the top of spring Isolator as shown in the figure.
3. Level the spring Isolator height and tighten the nuts and bolts properly after providing spring and plain washer.
Fix the whole assembly to the bottom frame in the fan section.
Note: Rubber mounts are used for smaller model up to CDHW -120.
Positioning and fixing of rubber mount / spring isolator at the specified

location is very important since the load carrying capacity of the springs are
different.
40
USER'S MANUAL
Vertical Extrusions Assembly

1. Refer the packing list .Pick up vertical A type extrusion and confirm the dimension of the extrusion.
2. Insert it in the glass filled nylon corner of the bottom frame assembly.You may hammer the extrusion by plastic
or rubber hammer / mallet for the proper fitment.
3. Rivet the extrusion with corner from out side. Rivet size is 3/16" x 1/2" long.
Ensure the length of A type extrusion before fixing it, otherwise it may create
the problem for vertical panel fitment.
41
Top Frame Assembly

1. Place the top frame on top of the vertical extrusion. Confirm proper support to the top frame to avoid the breakage
of corner.
2. Rivet them together as explained earlier. Diagonally, the frame dimensions should not be out by more than
1 - 2 mm.
3. Overall dimension of the frame should be equal to the length, width and height of the AHU.
Verify the diagonal distance after placing the top panel assembly and then only
rivet the frame with corners.
42
USER'S MANUAL
Blower and Motor Assembly

1. Put the self adhesive gasket on the flange of canvas connector and fix it on the cut out panel with the help of
aluminium rivet of dia 3/16" * 25 mm long .
2. Place the blower on the mounting channel such that the fan opening matches with the cut out of the panel.
Put the self adhesive gasket on the periphery of the fan opening .Fix the other end of canvas connector on
the fan opening with the help of rivet of size 3/16" * 25 mm .In case of up blast orientation of fan, spool is to be
provided in between fan opening and canvas connector.
3. Mount the motor on the motor mounting base plate and fit it with the help of M8 /M10/M12 Bolt with bigger dia
of plain washer and spring washer as per the rating of the motor
4. Refer the packing list and mount pulley on fan and motor shaft Align both the pulleys with the help of straight
edge .Mount the v-belt , give the proper tension to v-belt with the help of tension gauge .Tight the motor mounting
base plate on channel.
5. Fix both the end of spring isolator channel on A type extrusion by using rivets of size 3/16" * 25 mm .
6. Level the height of all the springs by using spirit level and tight the lock nut of the spring Isolator.
Ensure proper tension of V belt by using belt tension gauge.

Ensure the leveling of spring isolator height.
43
Coil Frame Assembly

1. Paste self adhesive foam gasket of size 20 x 3 mm on the end flanges of all four blank off of coil frame.
2. Paste self adhesive foam tape on top, bottom, and side plate of coil. Place the coil frame inside the unit and
position along the A or B type extrusion.
3. If the coil frame is placed on A type, then fix one side of coil frame on A type and other side on the sides of
coil with the help of self drill and tapping screw.
4. Screws for fixing top and bottom blank off should be fixed from air entry side. Ensure that the 175 mm side
coil frame blank off is fixed on the header side of the coil.
5. Once the coil is positioned properly, fixed the coil support on the A type with the help of self drill& tapping
screws of size 4.2 mm x 25 mm long.
Ensure the 175 mm width coil blank off is fixed on the header side of the coil.
44
USER'S MANUAL
Coil Assembly
1. Put the self adhesive foam gasket on the periphery of the coil flanges.
2. Position the coil on top of coil support channel which is fixed on the drain pan.
3. Header should be on 175 mm side of the coil frame. Coil inlet should be towards the blower side in the draw
through AHUs.
4. After positioning the coil, fix it with coil frame with the help of 4.2 x 25mm long self drilling and tapping
screws.
Coil inlet should be towards the blower side.
45
Side panel assembly

1. Refer the panel arrangement drawing and place the B type extrusion at specified distance and fix it with rivet
of size 3/16" * 12 mm long from inside of AHU.
2. Place the panel as per drawing and maintain equal gap of 2 3mm between extrusion and panel all around.
Insert the taper lock wedge inside the groove of A and B type of extrusion.
3. Mark the position of the coil header on the panel and make the hole on the header panel. Roll on the rubber
collar on the coil header on the either side of the panel.
Do not forget to put the sleeve and rubber collar on the header.
Taper lock wedge should be inserted in side the groove of the extrusion until
its step touches to extrusion
46
USER'S MANUAL
Door assembly
1. Keep 4 -5 mm distance from B type extrusion or A type extrusion depend on which the hinge is going to be
fixed to the edge of access door for the smooth movement of the door.
2. One end of the hinge is fixed on Btype or A type extrusion and other end is fixed on the door.
3. Fix the handle in the hole provided on the door.Also fix the view port with gasket.
Holes to be drilled on A type and B type extrusion and fit the nut sert in it for
fixing auxiliary and access door. Ensure the Nut sert machine is available at
site.
47
Filter frame
1. Put the self adhesive foam gasket on the periphery of filter frame. Mount the filter frame on A/B type extrusion
and fix it by self drilling and tapping screw..
2. Mount the filters in the filter grid. Filters will get automatically locked because of the spring action of the supports
provided in the filter frame.
48
USER'S MANUAL
Sticker Position
49
Recommended Tools
Tools required in the Assembly of Screwless AHU
50
Hand Drill Machine (Reverse/Forward) 1 No.
Rivet Machine with Jig (Manual) 1 No.
Nut Sert Machine (Manual)
Spanner 10mm One side Fix & One Side ring. 2 Nos.
Spanner 16/17mm Fix 2 Nos.
Spanner 24/25 mm Fix 2 Nos.
Adjustable Spanner 1 No. (Maximum Opening 40mm)
Ratchet Spanner set with socket 10mm, 13mm, 15mm, 17mm, 19mm, and 24mm.
Allen key set 1 No. of Inch and 1 No. of mm.
Screwdriver (Flat type 4 Inch and 8 Inch. Length)
Screwdriver (Star type 6 Inch. Length)
Tester 1 No.
Knife 1 No. (Small)
Pliers 1 No.
Hacksaw (frame with Blade)
Measuring tape 5m
Silicon RTV Sealant 1 No.
Plastic Hammer 1.5 Inch. - 1 No.
Rubber Mallet 4 Inch 1No.
Metal Hammer 250 g 1 No.
Spirit level 1 No.
Chisel 3 Nos.
Screw Bit for 4.2mm Dia, 25mm length Screw 5 No.
Screw bit Holder 150mm, 75 mm For 4.2mm Dia, 25mm length Screw
M6 Bolt Socket of Drill Machine 1No.
Hole Saw cutter and Arbor 25mm, 40mm, 60mm, 75mm, 100mm 1No Each.
Drill bit 5mm 10 Nos.
Drill Bit 6 mm 2 Nos.
Drill Bit 10 mm 2 Nos.
Drill bit 12 mm 2 Nos.
C Clamp 6" 4 Nos.
Carpenters Vice 12 Feet long 1Nos.
Try Square 1 No. 6 Inch long.
Belt Tension Gauge
Vacuum Cleaner 1 No.
USER'S MANUAL
Electrical Information
Connect the power supply in accordance with local regulations. Earth all equipment at each section.
All wiring must confirm to IS and IE rules and possible local codes.
The power characteristics, voltage, phase and frequency are stamped on the name plate of the motor.
Whenever possible, electrical conduit/cable should be run to the unit from the bottom of the side panel/skid.
If junction box is provided, electrical cable connection made to the junction boxes on units must be made on
the bottom of the box. Installation must comply with code requirements. The installation should be made
watertight.
All exposed electricals MUST be checked for tight fastening prior to actual
startup. A poor connection can cause overheating and component failure
through inadequate current handling capacity.
A motor connection diagram is affixed on the inside of the motor terminal box cover. Be sure that extra cable
length is made available at the motor to permit fan belt adjustment.
All fan motors are three phase; totally enclosed fan cooled (TEFC) types with squirrel cage rotors.
The fan motors for Ceiling Suspended direct driven types are with single phase.
Standard motors have radial flow fan allowing fully reversible rotation. The motors are dynamically balanced.
Bearings are greased for life with considerable grease reserve.
Terminate the cable for DOL or Star/Delta as the case may be.
Check the cable size with respect to motor rating from the approved electrical single line drawing.
Complete both the cable termination and required earthing.
The AHU starter panel should be close to the AHU. Otherwise provide an isolator switch (disconnect) or on/
off push button station near the AHU.
The marine light inside will need a single phase 230V, 50 Hz AC supply. Provide an MCB in the AHU panel.
The limit switch (for fan access door) should be wired in the control panel of the AHU starter.
51
Cooling Coil Installation

Coil Hand Selection
Coil hand connections (LHS or RHS) should depend on space availability for maintanance. Check the exact inlet
and outlet connection of the pipes to the coils. Water enters from the inlet nozzle at the bottom and exits at the
top. The water inlet should be at the air-leaving side.
General
Consult the job specifications and approved drawings for specific piping requirements, coil connection sizes
and location. The unit must be levelled to ensure proper venting and draining of coils. The piping arrangement
must be for a balanced flow in multiple coil installations.
The coil will meet performance ratings only if the air velocity is uniform over the face of the coil. High air velocity
spots on the coil may cause the carry-over of moisture from the coil. Low air velocity areas of the coil will not
deliver published rating. The duct connection must be designed to provide for uniform flow of air across the
face of the coil. In case of ducted return air, the entering duct must have a smooth transition from any high
velocity effects.
The heating coil will normally be for reheating. It must be located after the cooling coil in the direction of the air
flow.
Support all connecting piping independent of the coils. Provide swing joints or, preferably flexible fittings in all
piping connections, particularly adjacent to heating coils, to absorb expansion and contraction strains. Rigid
piping connection can cause coil damage.
The coils supply and return pipe connections are labelled. When connecting the piping to coil header; make
the connection only tight enough to prevent leaks. Excessive tightening may cause damage to the header.
52
USER'S MANUAL
Water Coils Drainable Water
Connect the water inlet to the bottom of the cooling

coil header on the air-leaving side of the coil and
the water outlet to the top of the header at the airentering side of the coil to achieve counter flow of
water and air.
Positive coil freeze protection must be used in
installations where any part of the coil is subjected
to temperature of 0 o C or lower. This may be
accomplished by using a suitable antifreeze
solution. If the coil is not in use, it is recommended
that the coil be completely drained and the inside
of the tubes blown dry with compressed air. Other
means of protection such as the full constant flow
of water can be used.
Direct Expansion (DX) Coils

Each coil must be installed with suction header towards the air-entering face of the coil and with the suction
connection at the lower end. The orientation of the refrigerant distributor is not critical but the distributor tubes
should not be pinched or bent in a non-uniform configuration. These coils are despatched from the factory with
Dry Air Pressure of 7-15 psig.
An individual expansion device must be provided for each coil at the field.
Thermostatic expansion valves are to be equipped with external equaliser connection that are field connected
to the suction lines. The valve should be sized in accordance with manufacturer's recommendations, allowing
approximately 35 psig pressure drop through the coil and distributor at full load. Do not oversize the valve. Follow
the manufacturer's instruction on the location of the thermostatic bulb. Proper expansion valve operation is
necessary in order to realise the rated coil capacity.
When a DX coil is operated with suction temperature below 00C, a build up of frost will occur on the finned surface.
It is, therefore, not recommended to use DX coils for airconditioning below freezing temperature. If the full load
operating point for the coil is selected at a safe temperature, a system analysis is required to check for the lowest
probable suction temperature at light load conditions. Suction pressure controlled hot gas by-pass valves are
available from various control manufacturers to maintain an adequate minimum suction temperature.
Air Velocity through Coils

The air velocity across the chilled water coil and direct expansion coils should be generally 2.54 m/sec. However
it must not exceed 2.8 m/s to prevent water carry-over. Air velocity, which is too low, will result in a low load situation
on the cooling coil, which will effect compressor operation. Air flow (m3/s) and air velocity (m/s) can be adjusted
by changing the fan/motor pulley sizes or by adjusting the fan outlet damper.
53
Condensate Drain Piping

The majority of cooling coils are located in the units so that the supply air is drawn through them. This results in
condensate being subjected to negative pressure. Unless some means of pressure equalisation is provided in
the condensate drain, the air rushing back through the drain pipe will cause the condensate to build up in the
drain pan. As the unit continues operation, the accumulated water will be carried with the air stream. A trap should
be installed to prevent this condensate water build up. On initial startup, it may be necessary to fill the trap manually
or, after the unit has operated for some time, to allow for a small unit to fill the trap automatically.
Drain Pan
Drain pan
G.I. Elbow
IN NO RUN CONDITION
NORMAL RUNNING CONDITION

TRAP
G.I. Elbow
DIFFERENTIAL
Drain Pan
G.I. Elbow
CONDITION WHEN AN START
TOTAL HEAD
Condensate Drain Trap and Line Installation

Install a trapped condensate drain line at unit drain connection.
For Draw Through applications, the trap dimension must be at least 1/2 inch greater than negative static pressure
in the unit drain pan area. To determine trap dimension, first determine the negative static pressure in the unit.
Always assume the worst condition, such as dirty filter in the return air circuit to the fan.
Example:
Negative Static Pressure
- 0.5" - 0.5"
Minimum of 1/2"
- 0.5" - 0.5"
Drain pipe size
- 1.25" - 1.0"
Trap
- 2.25" - 2.0"
For Blow Through units, the same practice is followed, but the drain leaving the drain pipe should not be above
the bottom of the drain nipple.
Provide adequate foundation height to accommodate trap.
Do not connect the AHU drain trap directly to any plumbing line. Contamination of air may take place. Condensate
drain pipe should be insulated to avoid sweating.
54
USER'S MANUAL
Air System
Duct Connection Guidelines

All discharge air duct connections to the unit may be directly connected only for Horizontal AHUs, Vertical
AHUs with multiple blower. All other AHUs, terminate the ducting through canvas connections. Duct turn and
transition must be made carefully to hold frictional losses to a minimum. Avoid short turns. Duct elbows should
contain splitters or turning vanes. Duct work connected to the fan discharge must run in a straight length for at
least two equivalent outlet diameters and should not be reduced in cross sectional area. A duct turn should be in
the same direction as the fan rotation.
Installations of the elbow and other abrupt flow area changes
directly at the fan outlet will cause system losses. These
losses must be taken into account during the design phase
and must be added to any field measurements.
Sound and Vibration Transmission

All Air Handling Units generate some sound and vibration that may or may not require special treatment of the air
handling duct/rooms. The noise generated by the air handling unit is dependent on the speed of the fan, the amount
of air, the type of fan and the static efficiency of the fan. In applications where sound and vibration transmission
may be objectionable, good acoustical engineering practices must be incorporated in the system design. It is
better to locate the AHU away from noise sensitive areas. The supply ducts should be internally lined. Silencers
may also be installed.
On units with return fans, it is especially important to consider
the effects of sound transmission into the conditioned space.
55
Pre-Start Up
Adjustment and Checks
Belt and Sheaves
Improper sheave alignment and belt tension are frequent causes of excessive vibration as well as shortened
belt and bearing life. The Vee Belts used are SPA, SPB , SPZ, SPC as required. Please check the above provided.
Air Filters
All filters are shipped loose. It is mandatory that filters be in place in the filter frames of each unit before putting
the unit into operation to protect the coil and keep them clean.
When the unit is first started, dirt and debris from the building/duct is likely to be sucked in. Hence, place a muslin
cloth in front of the filters to prevent them from getting choked.
Air Flow Control Dampers

Dampers are intended for use with individual controllers, actuators or manually.
Start-up checks
Have transportation restraints been removed?
Check supply voltage, in all three phases and voltage unbalance
Check fan's wheel and drive sheaves
Set screw tight and check drive alignment
Check bearing for alignment and locking collars for tightness
Rotate wheels and motors to ensure freedom of movement
Are drain traps of correct shape and size?
Check to see that proper air filters are installed
Check the AHU is connected to the duct
Check the fan outlet damper is operational
Operational Checks
Momentarily start the fan motor and ensure correct rotation
Check belt tightness
Check RPM of, and amperes drawn by, supply fan motor
Check cabinet for air leakage
Check cabinet for possible water leaks
Latch/Tighten all panels
56
USER'S MANUAL
Safety Checks
Be sure all door latches (locks) are secured before starting unit.
Fans are dynamically balanced at fan manufacturer's works. However, there are certain operating speeds at which
the natural frequency of the rotating member is attuned to the natural frequency of certain panels which are the
part of the enclosure. These vibrations can tend to reinforce each other in such a way that excessive vibration
can be encountered under certain conditions. It is difficult to predetermine such condition, as it is affected by
mounting arrangement, the various modules used in the make up of assembly and the duct connections and
operating condition.
Under no condition should the unit be allowed to operate when excessive unit vibration is apparent. Permanent
damage may result due to this.
After 24 hours of satisfactory operation, shut down the equipment and check all foundation bolts, shaft bearing
and drive set screws and tighten wherever required.
If the above check reveals no apparent discrepancies and vibrations still persist, the speed of the unit should be
lowered by approximately 10% to determine if a natural frequency is causing the vibration. If the unit contains
water coils, they must be filled when this check is made.
Trained personnel should be available at the time of start up
of the Air Handling Units.
Motor
Do not operate fan motors in overload amperage condition.
Do not energise the motor if earthing is not completed.
Before mounting the V belts, it is preferable to run the motor at no load condition and check the no load current
and verify the direction of rotation.
It is not desirable to run the AHU for long periods without providing filters and connecting to duct work since the
fan will draw more current and the coil will also choke with dust.
Motor amperage should be checked again after the connecting duct is installed and an air flow check made on
the air distribution system. Only in those cases where the airflow at the outlet is insufficient to meet specification
should the blower speed be changed. However, when the speed is changed, check the adequacy of fan motor as
BHP increases by an order of the cube of the ratio of increase in RPM. Also check the adequacy of switch gear.
Belt
Belt should be checked for correct tension at start up and should be checked again after 24 hours of operation.
On multiple belt adjustable pulleys, the pitch depth should be checked to ensure identical belt travel, power transfer
and wear. An adjustable motor base is provided for belt adjustment. Figure on page 43 illustrates the belt tension
guage.
Do not operate fan motor until lubrication has been checked
and drive adjusted.
If the motor operates at incorrect voltage or on 2 phases, the motor may draw full load current at no load condition.
57
Operation
Pre-Operation Check
Lock out electrical power to prevent accidental fan operation. Check the inside of the unit and duct work to
make sure that no loose nuts, bolts, trash, sheet metal parts etc. have been left behind, which may be sucked
into fan and result in permanent damage. At the same time, check to make certain that air filters have been
placed in the filter section, with fill pieces in place.
Recheck the tightness of the mounting hardware, set screws and locking collars on the bearing, and motor
mount adjustment nuts.
Rotate the fan shaft by hand to make sure that it is free and no obstruction has been caused during
transportation.
Check the bearing for proper lubrication by referring to the bearing lubrication instructions. At the same time
if the bearing contains locking collars, make sure that the locking collars have been locked in the direction of
the fan rotation.
All transportation hold nuts must be removed completely
to permit fan to ride freely on the isolators.
Recheck the fan and motor sheave alighment with a straight edge and belt tension for proper values.
Refer to the fan motor manufacturers instructions attached to the fan motor and check each item for compliance
prior to start-up.
Operational Check
After the pre-operational check, apply power to the motor for a short interval to observe that the fan is rotating
in right direction as indicated by arrow on the side of the blower scroll. Check the fan speed with tachometer.
Check the current drawn by motor with an ammeter. Correct rotation and speed if required. Do not exceed
maximum speed or amperage.
Stop the machine immediately if any unusual sound or

vibration occurs and recheck all items.
If the vibration continues, the belt should be removed from the drive and motor allowed to run unloaded to determine
if the motor shaft is possibly bent, if there are defective motor bearing or if the motor is unbalanced or the pulley
is out.
58
USER'S MANUAL
Maintenance
General
A programmed regular maintenance will avert possible costly and unexpected downtime. It is the responsibility
of the owner to provide the necessary maintenance for the Air Handling Units and coils. If a system failure occurs
due to improper maintenance during warranty period, BSL will not be liable for the cost incurred to bring the unit
back to satisfactory operation.
Removable access door fitted with viewport has been provided on all units for necessary maintenance and to
provide access to various components which in time may require replacement.
Note:
Filter used during building construction must be replaced with clean filter prior to the occupancy
of the building.
Periodic Maintenance
Every Month
Check the cleanliness of the filters and clean as required.
Examine the damper and operating linkages to ensure that each is free and operating smoothly.
Every Three to Six Months
Add grease (Servogem 3) to the fan shaft bearing as indicated by the schedule from the bearing manufacturer
which has been attached to the unit. The exact period between lubrication is related to the rotational speed
and the atmosphere surrounding the bearing.
For normal operating conditions, the grease should confirm to NL GL. Grade 2 consistency. It is important that
the grease be free of chemical impurities, moisture, and dust, metal particles or abrasives. The bearing should
be lubricated while the shaft is turning. The grease should be pumped in slowly until a slight bead forms around
the outside of the seals. This bead, in addition to an indication of the adequate lubrication, provides protection
against the entry of the foreign matter. Excessive grease should be removed from the internal bearing to prevent
it from being picked up by the fan. Dirt will collect on the fan and eventually cause imbalance, resulting in
vibration and component failure.
If the grease fitting must be changed, it is important to see that the locking pin is in place when the fitting is
replaced. If an adapter or grease fitting of improper size and length is used, the locking pin may be either too
tight or loose and can affect the alignment and re lubrication of the bearing.
Adjust the belt tension if necessary. Never use a belt dressing on the belt. If belt slips in spite of proper tension,
use a good grade of belt cleaner to clean the belt. Use the motor base plate for adjusting the belt tension.
Never use excessive tension as this could result in damaging
the bearing.
59
When it is necessary to replace one belt in a given set, the entire set of belts must be replaced by a matched
set. Check the lubrication instruction for the installed motor and lubricate the motor as indicated.
Inspect the condensate drain trap and ensure that it is clear and free.
Check the bearing locking collars or set screw for tightness. Inspect the coils for cleanliness. If necessary,
hose the coils down with a low pressure water hose or low pressure air.
Never use hot water or steam on refrigerant coils as
dangerous pressure can build up within the coil.
Every Year
Clean the fan and inspect the drain pan for sludge and foreign material. Clean if required.
Observe the operation of all dampers and make any necessary adjustment in linkages and blade orientation
for proper operation.
Inspect the coil for cleanliness. if necessary, hose the coil down with low-pressure water hose or low-pressure
air.
60
USER'S MANUAL
Winterising System Components

Freeze Protection
All Chilled Water coils can be damaged during freezing weather. Precautionary measures must be taken to prevent
freezing such as:
For all year operation and shut-down such as power failure, night shut-down and weekend shut-down, the
controls must be installed so that the valves will go to the full heat position, and all fresh air dampers go to the
full closed position. The water circulation pump must be kept circulating water through the coil and/or auxiliary
heat must be maintained inside the cabinet.
Drain each coil and related piping such as traps and make sure that all the areas are drained.
After draining, flush coils with antifreeze solution such as ethylene glycol. A solution of 50% ethylene glycol
and 50% water will protect freezing below zero at sea level.
Winterising Drain Traps

During the winter months when the cooling system is turned off and the unit is exposed to freezing condition, an
antifreeze solution should be poured in the condensate drain trap to prevent freezing and possible damage. The
condense drain trap may also be drained.
Dampers
Dampers, operators, control and linkages must be checked prior to applying power to the operators, making
sure nothing will obstruct the operation of the damper. Do not overdrive damper operator as this may cause damage
to the damper.
61
Removal or Reinstallation
of Components
Blower
Follow these steps to remove the blower from casing:
Remove the belts from the drive
Loosen the retaining bolts of the blower
Fix the clamp below the blower base as shown in figure below
Remove the blower retaining bolt completely
Remove blower
If a new blower is installed, make sure that the spring selection matches the blower and motor. The blower should
also be properly balanced.
Coil Replacement
Access to the coil is obtained by removing the connecting piping from the coil and the panels at each end of the
coil.
For direct expansion coils, it is necessary that the refrigerant be pumped down into the condenser and contained.
Under no circumstances should the piping joints in DX coils
be heated for unseating while refrigerant is within the coil.
Dangerous pressure, gases and fire can result.
62
USER'S MANUAL
Belt Replacement
Always replace belts as a matched set. Used belts will always be longer because of stretching and belts should
never be installed singly on a multiple drive.
The adjusting nuts on the fan motor should be loosened and the belt placed in the sheaves. Never place the belts
on the sheaves by using a screwdriver to try each belt over the rim of the sheaves. Once the belts are in place,
the sheaves on the fan shaft and motor should be checked with a straight edge for alignment. Check the middle
groove of each sheave when multi groove pulleys are used.
Next, adjust the belt tension using the adjusting bolts on the motor mount. Use a recognized gauge such as one
shown in figure for adjusting the tension.
To determine the deflection force required, use the formula:
Deflection = Belt Span / 64
Do not over tighten the belt or the bearing may get damaged.
The best tension for a belt drive is the lowest tension at which
the belt will not slip under the highest required load.
63
Installation
Double Skin Vertical Air Handling Units
These units are fully assembled at the factory, packed properly and despatched. Upon receipt at site, these units
are to be unloaded carefully as illustrated in this manual and lead carefully to the place of installation.
Vertical D S Air Handling Units, with single blower arrangement are not provided with canvass connection at the
factory. Canvass connections are provided within the unit at factory for units with multiple blowers.
Install these units at site on 25 mm thick ribbed rubber pads of size 150 mm X 150 mm (2 layers of 12 mm thick
each placed one on top of other with a GI sheet of same size in between) at four corners. Ensure that the units are
leveled properly.
The units with single blower outlet are to be connected through a fire retardant canvass connection to the ducting
at site. It is preferable to install a Volume Control Damper of opposed blade type at the blower outlet to adjust the
air quantity of the AHU. Units with multiple blower arrangement are not required to be provided with canvass
connection at site, whereas one Volume Control Damper is recommended to be provided in the ducting to adjust
the air quantity.
64
USER'S MANUAL
D S Ceiling-suspended
Air Handling Units
These units are fully assembled at the factory, packed
properly and despatched. Upon receipt at site, these
units are to be unloaded carefully as illustrated in this
manual and lead carefully to the place of installation.
Typical Ceiling suspension by fully threaded rods
These units are ceiling suspended with the help of 4

suspension rods. The anchor fasteners used for
suspending the units from the ceiling should be able to
withstand the weight of the unit. The Units can be
suspended from an M S structural work also.
Ensure that the corner pieces are provided at the bottom

of the vertical extrusion at all four corners as shown in
the following illustrations. These corner pieces are
shipped alongwith the units from the factory.
Bottom corners (supplied loose)
For critical and sensitive installations, where non

transmission of vibration is very important, special
suspension arrangement is to be incorporated while
suspending the units as shown.
Special isolator
(if required)
These units are not provided with any canvass

connection at the fan outlet from the factory. Hence fire
retarded canvass connection is to be provided at the
outlet of the unit prior to connecting to the ducting. It is
preferable to install a Volume Control Damper of
opposed blade type at the fan outlet to adjust the air
quantity.
65
Troubleshooting
If your Air Handling Unit is not functioning properly, do check the following before
calling for service.
Trouble
Air flow is less
Cause
Remedy
Filter clogged
Clean filter.
Cooling coil clogged
Clean cooling coil.
Belt loose
Tighten the V belt.
Low Voltage
Ensure that correct

voltage is available.
Volume Control Damper

stuck or partially closed.
Check and adjust the

volume control damper.
RPM of fan less
Check the rpm with

design and change pulley
if required.
Static pressure high
System static pressure

has increased.
Check with design.
Air leaving temperature

of cooling coil high
Chilled water in temperature

high
Ensure that the design

water temperature is
available at cooling coil
inlet.
Less water flow
Check any clogged

water strainer and clean.
Check water balancing.
Check any valve stuck
in partially open
position.
Accumulation of water
in AHU
Water carry over
66
Cooling coil clogged
Clean the cooling coil.
Quantity of air flow is more
Adjust the flow rate by

volume control damper or
changing the pulleys.
U trap not provided
Provide U trap in the

condensate drain line of
adequate depth.
Drain line clogged
Clean the drain line.
Air quantity too high
Adjust the air quantity.
Face velocity of coil high
Measure the velocity and

adjust to the design
value.
USER'S MANUAL
Trouble
Noise and vibration
AHU motor trips
AHU not starting
Cause
Remedy
Unbalanced impeller
Check the static

balancing at site. If
required get the impeller
balanced dynamically.
Unbalanced pulleys
Balance the pulleys.
V Belt loose
Tighten the V belt.
Change the pulleys to

obtain required air
quantity.
Low voltage
Ensure that correct

voltage is available.
Adjust the air quantity.
Two AHUs working in parallel

and one AHU stopped
Close the discharge

damper of the AHU not
working.
Faulty overload
Check the overload

and replace.
Single phasing
Check all the phases

and replace burnt out
fuse.
Low voltage
Check and ensure that

correct voltage is
applied.
Single phasing
Check all the fuses

and take corrective
action.
67
Preventive Maintenance
SOP (Standard Operating Procedure) for Pre Filter Cleaning
Aim: Routine cleaning of prefilter
Standard followed: As per filter manufacturer.
Scope of work: To monitor and verify cleanin of prefilter
Percentage of cleaning required: 100%
Note: Before starting work check the house keeping in Pre filter mounting room. Every worker should be in proper
clothing & should wash the hands with soap water before starting the process.
Steps to be followed for Pre Filter cleaning:

Step - A
a. Check the house keeping in the prefilters mounting area
b. Remove the dust with proper tools
c. Transfer the filters to cleaning area
d. Avoid cleaning filters near to the Air Handling unit
e. Take out the filters from covers individually.
f. Use 1.5 to 2bar compreseed air to clean
g. Clean the filters from the outlet side
h. The distance from air nozzle to filters should be 6 inch.
i.
Starting from one corner move the nozzle all over the area.
j.
Cleaning to be done anywhere between 2-5 minutes depending on size of filter and area of filteration.
k. After cleaning filter medium remove dust on the frame by cloth dipped in IPO.
l.
Transfer the cleaned filters to clean polythene cover and shit it to safe place.
m. Shift the cleaned filters to mounting area

n. Clean the mounting frames totally, any dust e.t.c. are not acceptable on finished filter
o. Fix it with appropriate fastners.
Final Ovservation
Tighten the fastners for no leakage of air.
68
USER'S MANUAL
Spare Parts List / CDHW

AHU MODEL
V-BELT
CODE
DISCRIPTION
QTY/AHU
CDHW - 035
SPZ-750
750
SPZ (1)
CDHW - 040
SPZ-750
750
SPZ (1)
CDHW - 050
SPZ-1000
1000
SPZ (1)
CDHW - 070
SPZ-1000
1000
SPZ (1)
CDHW - 080
SPZ-1000
1000
SPZ (1)
CDHW - 100
SPZ-1120
1120
SPA (1)
CDHW - 110/120
SPZ-760
760
SPZ (1)
CDHW - 135
SPZ-950
950
SPZ (2)
CDHW - 150
SPZ-950
950
SPZ (2)
CDHW - 160
SPZ-950
950
SPZ (2)
CDHW - 175
SPZ-1160
1160
SPZ (2)
CDHW - 190
SPZ-1160
1160
SPZ (2)
CDHW - 200
SPZ-1120
1120
SPZ (2)
CDHW - 220
SPA-1220
1220
SPA (2)
CDHW - 230/240
SPA-1220
1220
SPA (2)
CDHW - 255
SPA-1320
1320
SPA (2)
CDHW - 265
SPA-1320
1320
SPA (2)
CDHW - 290
SPA-1450
1450
SPA (2)
SPA-1220
1220
SPA (2)
CDHW - 325
SPA-1650
1650
SPA (2)
CDHW - 340
SPA-1650
1750
SPA (2)
CDHW - 355/370/390
SPA-1950
1950
SPA (2)
CDHW - 410
SPB-2000
2000
SPB (2)
CDHW - 430/445
SPB-2000
2000
SPB (2)
CDHW - 470/490/500
SPB-2150
2150
SPB (2)
CDHW - 520/540
SPB-2120
2120
SPB (2)
CDHW - 570
SPB-2120
2120
SPB (2)
CDHW - 600
SPB-2120
2120
SPB (2)
CDHW - 300
CDHW - 455
69
AHU MODEL
CODE
DISCRIPTION
QTY/AHU
CDHW - 035
AHF610617
Prefilter-EU3-AL-BOX-610W610H
CDHW - 040
AHF610617
CDHW - 050
AHF610617
CDHW - 070
AHF610617
CDHW - 080
AHF610617
AHF610309
AHF610617
AHF610309
AHF610617
AHF610309
AHF305614
AHF305309
CDHW - 135
AHF610617
CDHW - 150
AHF610617
AHF305614
AHF610617
AHF305614
AHF610617
AHF305614
Prefilter EU3-AL-BOX-305W610H
CDHW - 190
AHF610617
CDHW - 200
AHF610617
CDHW - 220
AHF610617
AHF610309
AHF610617
AHF610309
AHF610617
AHF610309
AHF610617
AHF610309
AHF610617
AHF610309
CDHW - 100
CDHW - 110/120
CDHW - 160
CDHW - 175
CDHW - 230/240
CDHW - 255
CDHW - 265
CDHW - 290
70
FILTER
USER'S MANUAL
AHU MODEL
FILTER
CODE
DISCRIPTION
QTY/AHU
AHF305309
AHF305614
AHF610617
AHF610309
AHF305309
AHF305614
AHF610617
AHF610309
AHF610617
AHF610309
CDHW - 355/370/390
AHF610617
12
CDHW - 410
AHF610617
12
CDHW - 430/445
AHF610617
12
AHF305614
AHF610617
12
AHF305614
CDHW - 470/490/500
AHF610617
15
CDHW - 520/540
AHF610617
12
AHF610309
AHF305309
AHF305614
AHF610617
15
AHF610309
AHF610617
15
AHF610309
CDHW - 300
CDHW - 325
CDHW - 340
CDHW - 455
CDHW -5701
CDHW - 600
71
AHU MODEL
CODE
DISCRIPTION
QTY/AHU
AHI065000
Rubber Mount : RM.19B
AHI068000
Rubber Mount : RM.19Y
AHI065000
AHI068000
Rubber Mount : RM.19.Y
AHI062800
Rubber Mount : RM.19R
AHI065000
Rubber Mount : RM.19.B
AHI065000
AHI065000
AHI065000
AHI062800
CDHW - 100
AHI062800
CDHW - 110/120
AHI062800
CDHW - 135
AHI251000
Spring isolator : OS 25-100
HI256000
Spring Isolator : OS 25-60
AHI251000
AHI256000
AHI251000
AHI256000
AHI251000
AHI251600
AHI251000
AHI251600
AHI251000
AHI251600
AHI251000
AHI251600
AHI251000
AHI251600
AHI251000
AHI251600
AHI251600
AHI252500
AHI251000
CDHW - 035
CDHW - 040
CDHW - 050
CDHW - 070
CDHW - 080
CDHW - 150
CDHW - 160
CDHW - 175
CDHW - 190
CDHW - 200
CDHW - 220
CDHW - 230/240
CDHW - 255
CDHW - 265
72
RUBBER MOUNT / SPRING ISOLATOR
USER'S MANUAL
AHU MODEL
CDHW - 290
CDHW - 300
CDHW - 325
CDHW - 340
CDHW - 355/370/390
CDHW - 410
CDHW - 430/445
CDHW - 455
CDHW - 470/490/500
CDHW - 520/540
CDHW - 570
CDHW - 600
RUBBER MOUNT / SPRING ISOLATOR

CODE
DISCRIPTION
QTY/AHU
AHI251600
AHI252500
AHI251000
AHI251600
AHI252500
AHI251000
AHI251600
AHI252500
AHI252500
AHI251600
AHI252500
AHI251600
AHI252500
AHI251600
AHI253000
AHI252000
AHI253000
AHI252000
AHI253000
AHI252000
AHI254000
AHI252000
AHI254000
AHI252000
AHI254000
AHI252000
73
AHU MODEL
LIMIT SWITCH
CODE
DISCRIPTION
QTY/AHU
CDHW - 035
AHL001600
Limit Switch LSR Bohmen make
CDHW - 040
AHL001600
CDHW - 050
AHL001600
CDHW - 070
AHL001600
CDHW - 080
AHL001600
CDHW - 100
AHL001600
CDHW - 110/120
AHL001600
CDHW - 135
AHL001600
CDHW - 150
AHL001600
CDHW - 160
AHL001600
CDHW - 175
AHL001600
CDHW - 190
AHL001600
CDHW - 200
AHL001600
CDHW - 220
AHL001632
CDHW - 230/240
AHL001708
CDHW - 255
AHL001752
CDHW - 265
AHL001828
CDHW - 290
AHL001862
CDHW - 300
AHL001914
CDHW - 325
AHL001914
CDHW - 340
AHL001994
AHL002006
CDHW - 410
AHL002537
CDHW - 430/445
AHL002071
CDHW - 455
AHL002120
CDHW - 470/490/500
AHL002071
CDHW - 520/540
AHL002071
AHL002084
AHL002149
CDHW - 355/370/390
CDHW - 570
CDHW - 600
74
USER'S MANUAL
AHU MODEL
CANVAS
CODE
DISCRIPTION
QTY/AHU
CDHW - 035
HACAZ1010
flexible canvas conn-10-10
CDHW - 040
HACAZ1209
CDHW - 050
HACAZ1212
CDHW - 070
HACAZ1515
CDHW - 080
HACAZ1813
CDHW - 100
HACAZ1818
CDHW - 110/120
HACAZ0450
flexible canvas conn-450
CDHW - 135
HACAZ0500
CDHW - 150
HACAZ0500
CDHW - 160
HACAZ0500
CDHW - 175
HACAZ0560
CDHW - 190
HACAZ0560
CDHW - 200
HACAZ0560
CDHW - 220
HACAZ0630
CDHW - 230/240
HACAZ0630
CDHW - 255
HACAZ0630
CDHW - 265
HACAZ0710
CDHW - 290
HACAZ0710
CDHW - 300
HACAZ0710
CDHW - 325
HACAZ0710
CDHW - 340
HACAZ0800
CDHW - 355/370/390
HACAZ0800
CDHW - 410
HACAZ0900
CDHW - 430/445
HACAZ0900
CDHW - 455
HACAZ0900
CDHW - 470/490/500
HACAZ0900
CDHW - 520/540
HACAZ1000
CDHW - 570
HACAZ1000
CDHW - 600
HACAZ1000
75
Spare Parts List / SDVW

AHU MODEL
SDVW - 035
SDVW - 050
SDVW - 070
SDVW - 100
SDVW - 140
SDVW - 170
SDVW - 200
SDVW - 250
SDVW - 270
SDVW - 300
76
V - BELT
ITEM CODE
DISCRIPTION
QTY/AHU
SPA-800
Belt ( 40 mm SP ),800-SPA-1
SPA-800
Belt (32mm SP), 800-SPA-1
SPA-800
SPA-800
SPA-1220
Belt (40mm SP),1220-SPA-1
SPA-1060
SPA-1060
SPA-1000
SPA-1060
Belt (40 mm SP),1060-SPA-1
SPA-1000
Belt (32 mm SP),1000-SPA-1
SPA-1120
SPA-1000
SPA-1250
SPA-1000
SPA-1400
Belt ( 40 mm SP ),1400-SPA-1
SPA-1120
Belt ( 32 mm SP ),1120-SPA-1
USER'S MANUAL
FILTER
AHU MODEL
ITEM CODE
DESCRIPTION
QTY/AHU
SDVW - 035
AHF400502
Prefilter-EU3-AL(400X500)
SDVW - 050
AHF600507
SDVW - 070
AHF400603
AHF500603
SDVW - 100
AHF500407
SDVW - 140
AHF500407
SDVW - 170
AHF600407
SDVW - 200
AHF500407
AHF600407
AHF500507
AHF600507
SDVW - 250
SDVW - 270
SDVW - 300
RUBBER MOUNT/ SPRING ISOLATOR

AHU MODEL
ITEM CODE
DESCRIPTION
QTY/AHU
SDVW - 035
AHI065000
RM 19 . 100 B
AHI068000
RM 19 . 100 . Y
AHI062800
RM 19 . 100 R
AHI065000
RM 19 . 100 . B
AHI062800
RM 19 . 100 R
AHI065000
RM 19 . 100 . B
AHI062800
RM 19 . 100 R
AHI065000
RM 19 . 100 . B
AHI062800
RM 19 . 100 R
4]
AHI065000
RM 19 . 100 . B
AHI062800
RM 19 . 100 R
AHI065000
RM 19 . 100 . B
SDVW - 200
AHI062800
RM 19 . 100 R
SDVW - 250
AHI062800
RM 19 . 100 R
SDVW - 050
SDVW - 070
SDVW - 100
SDVW - 140
SDVW - 170
SDVW - 270
SDVW - 300
77
CANVAS CONN.
AHU MODEL
DESCRIPTION
QTY/AHU
SDVW - 035
NR
SDVW - 050
NR
SDVW - 070
NR
SDVW - 100
NR
SDVW - 140
HACAZ1515
flexible canvas KAT 15X15
SDVW - 170
HACAZ1813
SDVW - 200
HACAZ1818
SDVW - 250
HACAZ0450
flexible canvas-450
SDVW - 270
SDVW - 300
78
ITEM CODE
USER'S MANUAL
Spare Parts List / DCW

AHU MODEL
V-BELT
ITEM CODE
DESCRIPTION
QTY
SDCW4017B
SPA-850
850
SPA(1)
SDCW4027B
SPA-850
850
SPA(1)
SDCW4035B
SPA-850
850
SPA(1)
SDCW4042B
SPA-850
850
SPA(1)
SDCW4050B
SPA-850
850
SPA(1)
SDCW4060B
SPA-950
950
SPA(1)
SDCW4070B
SPA-850
850
SPA(1)
SDCW4078B
SPA-850
850
SPA(1)
SDCW4085B
SPA-950
950
SPA(1)
SDCW4093B
SPA-900
900
SPA(1)
SDCW4100B
SPA-900
900
SPA(1)
SPA-800
800
SPA(2)
SDCW4110B
SPA-1060
1060
SPA(1)
SDCW4118B
SPA-1060
1060
SPA(2)
SDCW4127B
SPA-1090
1090
SPA(2)
SDCW4135B
SPA-1090
1090
SPA(2)
SDCW4035D
NR
SDCW4050D
NR
SDCW4070D
NR
79
AHU MODEL
CODE
DISCRIPTION
QTY
SDCW4017B
AHF600407
SDCW4027B
AHF500407
SDCW4035B
AHF500407
SDCW4042B
AHF500407
SDCW4050B
AHF500407
SDCW4060B
AHF500407
SDCW4070B
AHF500407
SDCW4078B
AHF400502
AHF500507
AHF400502
AHF500507
SDCW4093B
AHF610617
SDCW4100B
AHF400603
AHF500603
AHF305614
AHF610617
AHF305614
AHF610617
SDCW4127B
AHF610617
SDCW4135B
AHF610617
SDCW4035D
AHF500407
SDCW4050D
AHF500407
SDCW4070D
AHF500407
SDCW4085B
SDCW4110B
SDCW4118B
80
FILTER
USER'S MANUAL
AHU MODEL
RUBBERMOUNT/SPRING ISO/PAD
CODE
DISCRIPTION
QTY
SDCW4017B
AHI070000
Rubber Pad
SDCW4027B
AHI070000
Rubber Pad
SDCW4035B
AHI070000
Rubber Pad
SDCW4042B
AHI070000
Rubber Pad
SDCW4050B
AHI070000
Rubber Pad
SDCW4060B
AHI070000
Rubber Pad
SDCW4070B
AHI070000
Rubber Pad
SDCW4078B
AHI070000
Rubber Pad
SDCW4085B
AHI070000
Rubber Pad
SDCW4093B
AHI070000
Rubber Pad
SDCW4100B
AHI070000
Rubber Pad
SDCW4110B
AHI070000
Rubber Pad
SDCW4118B
AHI070000
Rubber Pad
SDCW4127B
AHI070000
Rubber Pad
SDCW4135B
AHI070000
Rubber Pad
SDCW4035D
AHI070000
Rubber Pad
SDCW4050D
AHI070000
Rubber Pad
SDCW4070D
AHI070000
Rubber Pad
81
Field Feedback Card

Product:
Air Handing Unit
AHU Model:
Unit Sr. No. :
Customer Name :
Location :
Date :
Observation
Quality of Packing
Comments
Details of Defects
OK / Damaged
Receipt of Documents
-
Packing List
Yes / No
Panel Arrangement Drawing
Yes / No
Condition of Parts :
-
Aluminium Extrusion
OK / Damaged
Puf Panels
OK / Damaged
Hardware
OK / Damaged
Drain Pan
OK / Damaged
Fabricated Frames
OK / Damaged
Coil
OK / Damaged
Blower
OK / Damaged
Motor
OK / Damaged
Drive Set
OK / Damaged
Filters
OK / Damaged
Dampers
OK / Damaged
Remarks :
Checked by
For Factory Use :
82
Date of Receipt :
Comments :
- Action By :
USER'S MANUAL
Field Commissioning Report

To be filled on Com
Product:
Air Handing Unit
AHU Model:
Unit Sr. No. :
Customer Name :
Location :
Date :
Observation
Comments
Details of Defects
Performance Checks :
-
Assembly
OK /
Installation
OK /
Commissioning
OK /
Air Quantity ( CMH / CFM )
Static Pressure ( Pa / mm )
Blower ( RPM )
Motor Current ( Amps )
Noise Level ( dba )
Vibration
OK /
Air balancing, If done at site
Yes / No
Change in Pulley Size at site
Yes / No
Others, if any
Commissioning Date
Commissioning By
Remarks :
Note: Warranty will be valid only after receipt of this form at Factory.
For Factory Use :
-
Date of Receipt :
Comments :
- Action By :
83
WARRANTY CLAIM FORM FOR AHU

(A copy of this form is to be filled in case of AHU failure, by BSL Engineer)
Location (City) ______________________________
Date ______________
AHU MODEL NO:
AHU Serial No
Date of despatch
Warranty commencing date
Application in which the equipment used
Date of Commissioning
Warranty expiry date
Customers Name and Address
Dealers Name and Address
Starting problem
Noise at starting
Yes
Yes
Yes
No
No
No
Noise while running

If there is noise, indicate the type of noise from the list __________________________________________
Blower Fan: Unbalanced, Vibration, Rubbing, Shaft bent.
Electric Motor: Jammed, Bearings failed, Internal noise, Burnt out. (Check voltage, current, insulation resistance).
Voltage at each phase
Yes
Yes
Yes
Voltage at each phase to phase

Insulation resistance (Megger test)
No
_______________ Mohms
Any leakage in the coil
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Electrical problem
Three phase balanced
Filters clogged
Filters worn out
Condition of V Belts
Belt tension correct
Alignment checked
All bolts of Fan/Motor tightened
No
No
No
Yes
No
No
No
No
No
No
No
Signature & Seal of Customer
Signature & Seal of BSL Engineer
Date: ________________
Date: ________________
(For factory use)
Claim Settled
Credit Advice No._________________
Claim Rejected
Reasons for rejection _________________________________________________________________
Settlement authorised by: _____________________
Date: _____________________
84
USER'S MANUAL
Warranty
Blue Star AHUs carry a warranty for a period of 12 months from the date of commissioning
or 15 months from the date of delivery, whichever is earlier, unless stated otherwise in
the contract of sales.
Warranty coverage shall be applicable from the date of receipt of Field Commissioning
Report (see page 75) at Blue Star Bharuch Factory.
While filing a claim for Warranty repairs, please allow our representative to fill in the
Warranty Claim Form (see page 76) and send it to Factory for speedy Warranty repairs.
Terms of Warranty
Blue Star extends a comprehensive Warranty on its systems, which entitles the customer to
the following:
1. Repair/reconditioning, by BSL/BSL Dealer, through whom the machine has been purchased,
of any part of the equipment found defective within 12 months from the date of commissioning
or 15 months from the date of despatch whichever is earlier.
2. The warranty is valid only if:
2.1 Installation and commissioning is taken care of by BSL/their authorised persons.
2.2 The equipment is operated as per the Companys operating instructions.
3. The above said warranty does not cover the following:
3.1 Consumables such as V belts, air filters etc.
3.2 Deterioration or failure of equipment due to corrosive atmosphere.
4. This warranty is not valid if any repair and/or modifications are carried out by the customer
himself or his representative without written concurrence from Blue Star Limited.
5. The guarantee extended herein is in lieu of all implied conditions/warranties under the law
and is confined to the repairs or replacements of defective parts and does not cover any
consequential or resulting liability damage or loss arising from such defect. Furthermore,
the guarantee in no case, shall extend to the payment or any monetary consideration
whatsoever of the replacement or return of the AHU as a whole.
6. Any repair/replacement shall not extend the overall warranty period as specified above.
7. The cost of transportation of material and of persons beyond Municipal jurisdiction shall be
borne by the customer.
8. This warranty may be read in conjunction with any other warranty on the installation as a
whole, if the AHU is supplied as part of a project.
85
Service Centres
EAST
SOUTH
WEST
BHUBANESHWAR
3A, Satya Nagar,
2nd Floor,
Bhubaneswar 751 007.
Tel: (0674) 2508270 / 2508239
BANGALORE
Ozone Manay Technology Park
Sy. No. 56/18 & 55/9
Hongasandra Village
Begur Hobli,
Garvebhavipalya
Bangalore 560 068
Phone : 41854000
AHMEDABAD
2nd Floor, Shivalik - II,
Near Shivranjani Cross Roads,
132 Feet Ring Road, Satellite,
Ahmedabad - 380015.
Tel: (079) 40224000
GUWAHATI
New Star Freeze Building
2nd Floor,
Opp. Kunjalata Bibah Bhawan,
G. S. Road,
Guwahati 781 005.
Tel: (0361) 2340619 /
2340620
KOLKATA
7, Hare Street
Kolkata 700 001.
Tel: (033) 22134200 /
22106609
NORTH
CHANDIGARH
SCO 1, Madhya Marg, Sector 26,
Chandigarh 160 019.
Tel: (0172) 2790482 /
5004000
JAIPUR
A-19, Main Sahakar Path,
Near Sahakar Bhawan,
Jaipur - 302 001.
Tel: (0141) 5124898 / 2744033
LUCKNOW
177/4, Faizabad Road,
Lucknow 226 007.
Tel: (0522) 4034000
NEW DELHI
E-44/12 Okhla Ind. Area
Phase II, Ohkla
New Delhi 110 020.
Tel: (011) 41494200 / 000
86
CHENNAI
104, Garuda Building,
Cathedral Road,
Chennai 600 086.
Tel: (044) 42444200
28116707- 8
KOCHI
2nd Floor, Millennium Plaza,
MKK Nair Road,
Alinchuvadu Junction,
Kochi 682 024.
Tel: (0484) 4499000
SECUNDERABAD
207, Sikh Road
Bantia Estates
Secunderabad 500 003.
Tel: (040) 27847553 /
27842057-58 / 27815469
TRIVANDRUM
T.C. IX/1490
Chandrika,
Sasthamangalam
Trivandrum 695 010.
Tel: (0471) 2720025 / 2720065
VISAKHAPATNAM
D. No. 49-24-65/1,
Near Sankarmattam Road,
Madhura Nagar,
Visakhapatnam 530 016.
Tel: (0891) 2748405 /
2748433
BHOPAL
Star Arcade, 2nd Floor
Plot No.165A & 166, Zone-I
Maharana Pratap Nagar
Bhopal 462 011.
Tel: (0755) 2553378 /
4273378 / 79
GOA
1st Floor,
Buddhaseth Apartments,
Tonca, Caranzalem,
Goa 403 002.
Tel: (0832) 2461671 / 2462087
MUMBAI
Blue Star House
9A, Ghatkopar Link Road
Saki Naka, Mumbai 400 072.
Tel: (022) 66684200 / 66684000
NAGPUR
219, Bajaj Nagar, 1st Floor,
South Ambazari Road,
Nagpur 440 010.
Tel: (0712) 2229244 / 2249000
PUNE
201/A, Nityanand Complex
1st Floor, 247/A
Bund Garden Road
Pune 411 011.
Tel: (020) 41044000 / 26113031
26127230 / 26122307
VADODARA
Ramakrishna Chambers
7th Floor, Productivity Road
Alkapuri, Vadodara 390 005.
Tel: (0265) 2338561 / 2332021 / 22
USER'S MANUAL
For any
assistance,
CALL:
Blue Star Service:
Ph: ............................................................
Cell: ..........................................................
Blue Star Dealer:

Ph: ............................................................
Cell: ..........................................................
Blue Star Regional Manager:

Ph: ............................................................
Fax: ..........................................................
Blue Stars/Dealers engineer to fill

above details before handing over
this Manual to customer.
87

Bluestar AHU

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What are the different types of air handling units described in the manual?

What are the different types of air handling units described in the manual?

What are some of the features described for the different air handling units?

What are some of the features described for the different air handling units?

Double Skin Air Handling Units

DOUBLE SKIN AHUs SCREWLESS

First published February 2009

Features of Double Skin Horizontal Floor Mounted AHU ...........................................................

Technical Data .............................................................................................................................

Features of Double Skin Vertical Floor Mounted AHU ................................................................ 10

DOUBLE SKIN AHUs SCREWLESS

Advantages of new Screwless Cabinet construction:

Reliability and Longer Life

High Indoor Air Quality

Ease of Assembly and Maintenance

Reduces Air bypass in Filter Section

Standard Filter Sizes

DOUBLE SKIN AHUs SCREWLESS

Standard features of the Units:

Double skin sandwiched panels:

The AHU base frame is of 14 G GSS and of 80 mm height.

AHU Overall Dimension

Standard Coil Size

Fan & Motor Details

Double Skin Floor Mounted Horizontal Draw Through Units

Operating Wt. (Approx)

DOUBLE SKIN AHUs SCREWLESS

Tube High Coil Area

Standard Coil Size

Double Skin Floor Mounted Horizontal Draw Through Units

DOUBLE SKIN AHUs SCREWLESS

LENGTH WIDTH HEIGHT

Floor Mounted Vertical Double Skin Air Handling Unit

KAT 18/13S2L 430*478 - 2 #

KAT 15/15S2L 471*404 - 2 #

DVW - 4 - 300 17708 30080

FLAT FILTER SIZE (48mm THK.)

Frontal Flat Filter Sizes

DVW - 4 - 270 16233 27574

DVW - 4 - 250 14444 24536

DVW - 4 - 200 11736 19936

DVW - 4 - 170 10000 16987

Vertical Double Skin Air Handling Unit

DOUBLE SKIN AHUs SCREWLESS

DCW4SL-060-B 1048 2200

DCW4SL-070-B 1048 2200

DCW4SL-078-B 1048 2130

DCW4SL-085-B 1048 2130

DCW4SL-093-B 1099 2097

DCW4SL-100-B 1099 2097

DCW4SL-110-B 1149 2333

DCW4SL-118-B 1149 2333

DCW4SL-127-B 1149 2638

DCW4SL-135-B 1149 2638

(b) Belt Driven Type

Standard Coil Size

DCW4SL-070-D 1048 2200 556

DCW4SL-050-D 948 1743 556

Standard Coil Size

DCW4SL-035-D 908 1238 556