MANUAL

INSTALLATION
OPERATION
MAINTENANCE

Double Skin Modular Air Handling Unit

MODELS DM AHU
DA AHU
DS AHU
AHUR VRV AHU

VER: O-AHU01-AUG19-12

The design and construction are subject to change without any notice for future improvement.
Table of Contents
1. General ....................................................................................................................1
2. Shipment ..................................................................................................................1
3. Handling / Rigging .....................................................................................................2
4. Storage ....................................................................................................................2
5. Assembly and Installation ........................................................................................... 2
6. Commissioning and Operation ................................................................................... 12
7. Maintenance ........................................................................................................... 14
8. Trouble Shooting ..................................................................................................... 16
9. Appendix ................................................................................................................ 17

1. General 1.4 Unit Decommissioning and

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

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

5. Assembly and Installation

5.1 General
The system design and installation should
follow accepted industrial practice, such as
described in the ASHRAE Handbook.
These units are not designed to be
weatherproof (unless equipped with
canopy) and therefore should not be
Figure 1 - Lifting method when offloading units installed outdoors. Flexible connections
should be used on the outlet and inlet
Transportation on the building site should duct connections for all units. A minimal
be done using forklift truck or a crane amount of air leakage is normal on the
(See Figure 2). The forks must only be cabinet and it will not affect unit
applied under the unit base frame and not performance. The air handling units are
against the panel. In case when fork of not design to be suspended from the top
the forklift is too short then suitable of the unit. Therefore, when the unit is
extensions should be used. ceiling hung, make sure unit is supported
with a base rail of channel.

5.2 Foundation
Adequate space should be left around the
unit for coils & drainage piping, filter
replacement, and maintenance. (See
Figure 3). If site access space for coil is
not follow recommendation, AHU need to
dismantle for coil replacement. The unit is
installed at a height that allows the
Figure 2 - Transportation by forklift truck
installation of condensate drain trap.

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 The section joints are pre-installed on
cabinets and base frames as shown in
Figure 7 (For AHU combination of 2
sections and above). The joint for side will
located outside of AHU, joint for top
bottom will be located inside of AHU.

Figure 3 – Recommended minimum service

clearances

To minimize noise transmission, insulation

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

To join two sections, install and level the

first section in position, then push the
second section close to the first section
after the alignment is correct as shown in
Figure 8.
Figure 4 – Air handling unit Plinth Foundation

5.3 Section Joint

Units that shipped in sections must be
carefully assembled to desired unit
arrangement. The air handling units are
design to use section joint brackets to
combine two sections. Section joints for
cabinet and base frame are shown in
Figure 5 and Figure 6. (provided when
cabinets are joined by intermediate-post
to intermediate-post arrangement)

Figure 5 – Cabinet Section Joint

Figure 8 – Combine cabinets

Base frame section joints need to join with

bolts and nuts as shown in Figure 9.
Figure 6 – Base Frame Section Joint

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 Figure 9 – Tighten the base frame section joint

After base frame being joined, further

tighten the external cabinet section joint.
After the external section joints being
connected, then only followed by internal
section joints. Make sure all joint brackets
provided are tighten with bolt and nut as Figure 11 – Section Joint for pentapost to pentapost
or different width cabinets
shown in Figure 10. All the bolts and nuts
for the joining are provided and packed
Lastly, silicone sealant need to apply to in-
with the unit.
between section to seal the gap.

5.4 Vibration Isolator

Air handling unit fans are supplied with
internal vibration isolators.

5.4.1 Spring Vibration Isolator

For model with spring isolators, temporary
Figure 10 – Tighten the cabinet section joint transport brackets are fitted to prevent
damage during shipment. All transport
WARNING brackets must be removed after
CABINET SECTION JOINTS ARE NOT installation and before commissioning.
INTENDED FOR LIFTING PURPOSE (See Figure 12)
AND PULLING CABINET FROM A After removing the transport bracket,
DISTANCE TO JOIN SECTION adjust the spring’s height accordingly to
TOGETHER. ensure the frame is level before
commissioning. Before turning the
When the cabinets are penta-post to adjustment nut, the locking bolt must be
penta-post arrangement or joining two loosened. Turn the adjustment nut bolt
sections with different cabinet width, then clockwise or anti-clockwise to decrease or
below type of section joints will be increase the spring’s height. Tighten the
provided. (See Figure 11) locking bolt after completing the
adjustment. (See Figure 13)

Figure 12 – Removing of transport bracket

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 Standard Air Series VRV AHU

Figure 13 – Spring Isolator Adjustment

5.4.2 Restrained Vibration Isolator Figure 16 - Standard Air Series VRV AHU Unit

The following is applied for plenum or 1. Outdoor unit

other fan which is using restrained spring 2. Control box
isolator. (See Figure 14). 20mm U-shaped 3. Air Handling unit
plates are inserted between top plate and 4. Field piping (field supply)
base plate when shipped out from factory.
5. Expansion valve kit
(See Figure 15). 6. Outdoor unit power supply
7. Control box wiring
8. Air handling unit thermistors
9. Power supply and control wiring
for air handling unit and controller
10. Air thermistor control for AHU
11. Remote controller

Outdoor Air Series VRV AHU

Figure 14 – Restrained Spring Isolator

Figure 17- Outdoor Air Series VRV AHU Unit

Figure 15 – Removing of U-Shaped Plate 1. Outdoor unit

2. Control box
5.5 Arrangement (VRV AHU) 3. Air Handling unit
Control box and expansion valve kit are 4. Microtech III
installed on the air handling unit. Figure 5. Field piping (field supply)
16 and Figure 17 show the proposed 6. Expansion valve kit
arrangement of component. Item 2, 3, 5, 7. Outdoor unit power supply
8 and 10 in Figure 16 and Item 2, 3, 6, 9 8. Control box wiring
in Figure 17 will be supply by factory. 9. Air handling unit thermistors
Refer to Installation and Operation manual 10. Control wiring for control box and
of “EKEQMCBAV3 / EKEQFCBA – Option kit Microtech III
for combination of Daikin condensing units 11. Power supply and control wiring
with air handling units” for further for air handling unit and controller
instructions. 12. Remote controller

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5.6 Coil Installation/ Pipe Connection Figure 19 shows the correct mounting
method and the position of TXV sensing
5.6.1 General bulb according to the piping size.
The coil will perform as per rating only if
IMPORTANT
the airflow is uniformly pass-through the
coil surface. AFTER PIPE-WORK DONE, SITE
INSTALLER MUST WRAP THE PIPE
CONNECTION WITH INSULATION
IMPORTANT
AND SEAL THE HOLES BETWEEN
HIGH VELOCITY SPOTS ON THE COIL
PIPE CONNECTIONS AND PANEL.
MAY CAUSE MOISTURE CARRY OVER.
THEREFORE, UNIFORM AIRFLOW 5.6.2 Water Coil
ACROSS COIL SURFACE IS CRUCIAL.
Water supply, water return, drains and
External pipe-work must be adequately vents connections are extending through
supported to ensure load-free towards coil the end panel of the coil section. All
connections. Swing joints or flexible connections are labeled on the end panel.
fittings are to be provided in all piping For control equipment, follow
connections, particularly those adjacent to recommendations from the manufacturer
heating source, to absorb expansion and regarding the types, sizing and installation
contraction strains. Failure to comply will of equipment. Hot water coils are not
result in damage to the coils & headers. recommended to be used with entering air
below 40oF (4.4oC).
IMPORTANT
5.6.3 Winterizing Water Coils
TO AVOID DAMAGING THE COIL
CONNECTIONS AT COIL HEADER, IT Coil freeze-up may occur due to air
IS ESSENTIAL TO HOLD THE stratification, failure of outdoor air
CONNECTOR / PIPE WITH TOOLS dampers and/or preheat controls. Routine
WHILST APPLYING COUNTER FORCE draining of water coils for winter shutdown
TO TIGHTEN THE JOINT. (See Figure cannot guarantee zero freeze-up incidents,
18) which may result in coil damage. It is
recommended to completely drain the coil
and treated with anti-freeze solution.
Fill each coil independently with an anti-
freeze solution by using a small circulating
pump follow by complete draining. Check
the freezing point of anti-freeze before
proceed in each coil. Diluted effect
normally occurred due to a small amount
of water always remaining in each coil.
Therefore, ensure sufficient amount of
Figure 18 – Coil header connection method anti-freeze solution be remained in coil to
prevent freeze-up.

5.6.4 Direct Expansion Coils

For each coil, individual expansion devices
must be provided for header suction
connection. If the air flow through two or
more coils in parallel or stacked coil bank,
the suction piping must be installed in
such a way that refrigerant from one coil
suction header cannot reach another coil
suction header. The bulb for the control
valve must be attached to the header or
the coil or section of coil fed by valve and
Figure 19– Bulb orientation and position not to a common header. When two or
more coils are connected to a common

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suction line, never place the bulb on the
common line.
Thermostatic expansion valve is to be
equipped with external equalizer tubes
that are field connected to the suction line.
The valve should be in accordance to the
manufacturer recommendations, allowing
approximately 35-psi pressure drop
through the coil and distributor at full load.
Do not oversize the valve, proper
expansion valve operation is necessary in
order to realize the rated coil capacity.

IMPORTANT
CAREFULLY READ THROUGH
Figure 20 – Drain Trap Arrangement
MANUFACTURING INSTRUCTION
FOR APPLING ANTI-FREEZE
5.7 Electrical Installation
SOLUTION. SOME PRODUCTS WILL
HAVE DIFFERENT FREEZING POINT Electric connecting should be compliant
IN ITS NATURAL STATE WHEN with relevant local laws and regulations.
MIXED WITH WATER. COIL FREEZE- All installation and management activities
UP IS NOT THE RESPONSIBILITY OF must be carried out by qualified personnel.
MANUFACTURER Refer to the specific wiring diagram and
It is not recommended to operate DX coil electrical component manual are attached
for air-conditioning purpose at below with the product before electrical
freezing suction temperature, 0oC which installation.
will result frost build-up at fins surface. If
the full load operating point for the coil is IMPORTANT
selected at a “safe” temperature, a system MAKE SURE ALL THE ELECTRIC
analysis is required to check for the lowest POWER DISCONNECT AND SECURE
probable suction temperature at light load FROM SWITCH ON BEFORE DOING
condition. WIRING CONNECTION

5.6.5 Piping Diagram (VRV AHU) 5.7.1 Motor Connection

For piping diagram of VRV AHU model, The electric supply to the motor must
please refer to the VRV ED or refer to correspond to the rated voltage stated in
manufacturer for advices. motor nameplate and be in conformance
with the National and Local Electric Code
5.6.6 Drain Pan Trap
and Regulations. Motor supplied able to
Drain pipes and traps must be at least operate within 10% tolerance from the
same diameter as the drain pan nameplate voltage. Motor connection
connection. Drain pan must be level to details are contained in the cover of the
permit condensation from coil drain freely motor terminal box. (See Figure 21). The
for the recommended depth and distance fan section metal frame must be grounded.
of drain trap installation. (See Figure 20) Suitable electrical protection isolator
Drain pan are not designed to be walked should be installed to protect the motor
on. and other electrical equipment.
Flexible conduit must be used when wiring
up fan motors to allow the fan motor to
move freely on its anti-vibration mounts.
Cables passing through panels must be
made with gland or grommet.
For inverter control, refer to the VFD
manual for wire size and requirements.

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 adjust belt tension using the adjusting
screw and nuts on the motor base.
Use recognized belt tension gauge to
check the belt tension by apply a force
large enough at the center of the belt to
deflect the belt by 16mm per meter (See
Figure 25). The deflection force for any
belt should be within the minimum and
maximum force shown in table 1. Readjust
the tension to maximum value when it
drops to min. value. The deflection force
of factory setting is based on “Initial
Fitting”, re-tensioning as “Retension” after
the unit has run for 24 hours.

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

Figure 21 – 3 phases motor connection diagram

5.7.2 Motor Cabling

Motor wiring must go downward from
motor terminal box to prevent
condensation water flowing into motor Figure 23 – Alignment of belt pulley
and lead to a failure. (See Figure 22)

Figure 22 – Motor Cabling

5.8 Drive Belt & Sheave

Figure 24 – Belt tensioning
Improper sheave alignment and belt
tension can cause excessive vibration,
premature failure of belts and bearings.
See Figure 23 for correct motor sheave
and fan sheave alignment.
Tensioning of the drive belt is achieved by
moving the motor in relation to the fan
(See Figure 24). When inserting new belts,
do not force belts over grooves, Loosen
the adjusting screw at motor base until
Figure 25 – Belt deflection distance
belt can slide smoothly over the grooves.
When all belts are in position, proceed to

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 Table 1 - Belt Tensioning Force
Deflection Force (N)
Pulley
Belt Section Initial Fitting Retension
Diameter
Min Max Min Max
SPZ <70 12 17 12 16
71-90 15 22 15 19
91-125 19 27 19 24
SPA <100 20 29 20 25
101-140 27 39 27 34
141-200 32 47 32 40
SPB <160 36 54 36 46
161-224 46 67 46 58
225-355 53 79 53 69
Refer to factory specifications for tension values that are not included
Refer to the diameter of smaller pulley

Table 2 - Adjusted Pitch Diameter

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

5.9 Accessory Items they are integral with central plant control
or associated ductwork under negative
5.9.1 Filter pressure condition.
Air handling units can be supplied with flat
5.9.3 Variable Pitch Pulley
filters and/or bag filters. There are 2 types
of filter frame, sliding frame or universal Modifications of the pulley diameter must
clip. Insert the filter into the frame by be done when stationery by moving the
following airflow arrow indicated. adjustable flange. Each complete rotation
of one of the two disks results in a
5.9.2 Mixing Box variation of the pulley diameter. (See
Fresh air and return air dampers can be Table 2 & Figure 26) When the required
linked together and drives by the same diameter is obtained, adjustable flange is
actuator if both are same size. Care must locked by tighten the four clamp screws.
be taken to ensure dampers are in open To get the same diameter in the two
position while the fan is running whether grooves of pulleys, screw the two mobile
flanges on the central flange. Then

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unscrew the two mobile flanges by the load-free toward cabinet collar when initial
same number of turnings to get the positioned.
required diameter. Compliance with the Codes of Practice in
Note that the belt centre line shifts when duct assembly and acoustic layout are
diameter changes. Driven pulley may need necessary to ensure the best possible
realignment. performance of the unit whilst avoiding
excessive pressure loss in the duct system
and minimize undue air stream noise. Duct
connections to and from units should allow
straight, smooth airflow. Sharp turns in
the fan discharge should be avoided,
particularly turns opposed to wheel
rotation. Turning vanes should be used.
Discharge plenums or any abrupt change
in duct should be avoided.

Figure 26 – Variable Pitch Pulley

5.9.4 Heat Wheel

Follow Heat Wheel manufacturer
recommendations for proper installation
procedure. Apply silicone to air leak spots
at baffle plates. (If applicable)
Refer to assembly of heat wheel baffle
plates at Appendix 9.1 when the heat
wheel section not able to ship in complete
build up. Figure 27 – Discharge duct layout

5.9.5 Heat Pipe Notes:

After installation of Heat Pipe with refers 1. Elbows should not be closer than
to manufacturer recommendations, site 2-1/2 times the Duct Equivalent
installer to install heat pipe baffle plates at Diameter. (Refer to Formula 1)
site, this is to avoid air bypass heat 2. Dampers should be placed at least
pipe/main cooling coil from top and side. fan diameters downstream of the
(If applicable) fan discharge.

5.9.6 Electric Heater

Power supply to electric heater and
electric connection is in accordance with
wiring diagram in terminal box of electric
heater.
The rated voltage of electric heater is
240V, single phase. Formula 1 - Duct Equivalent Diameter

IMPORTANT All duct joints, edges, opening area of top

IT IS ADVICED TO INTERLOCK roof (example: top discharge, top damper
ELECTRICAL HEATER WITH and top roof with opening), must have
BLOWER TO ENSURE HEATER IS skirting and fully sealed to avoid leakage
NOT ENERGIZED WHEN THERE IS and rain water seepage into the unit (if
NO AIR FLOW. unit is placed outdoor).

5.10. Ductwork
Connections to unit cabinet are made by
site drilling into the frame on the unit inlet
or fan discharge collar. This should be

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 5.11 Assembly of Complete Knock
Down Unit (CKD)
Due to container size constrain, some air
handling units are packed in unassembled
condition - CKD method. All parts required
are packed in section by section. It is
recommended to open one section at a
time to avoid confusion when assembly.
For CKD, additional drawing will be
provided for assembly at site.

5.12 Component Removal and

Replacement

5.12.1 Panel Removal

To remove side or top panel, simply
unscrew the fasteners located along the
Figure 28 – Site to seal gap between roof and duct aluminum clip on the frame of Air
Handling unit cabinet. Once the aluminum
clips are removed, lift the panel off.
5.12.2 Fan / Motor
The fan shaft, motor and drive
components can be removed and replace
through the access door opening or side
panel removal if additional access required.
For fan replacement, the entire fan
assembly can be pulled out from side or
Figure 29 – All edge to be seal by site if the flange
was sent separately / unit is CKD
front (for top discharge) of the cabinet.
Dismantle the intermediate fan supports
For outdoor unit, the return duct should and canvas follow by loosening bolts &
be large enough to cover the exposed nuts at motor and drive belts. Then
area of AHU to prevent rain water from remove the belts and nuts from Fan
seeping into the unit. mounting frame. Take out the fan and
replace with new fan with care. Re-
connect the shaft and bearings and fan
assembly.
5.12.3 Coil
The coil can be pulled out from side or top
of cabinet. The coil is fastened with bolts
Figure 30 – Front view of Return duct to be large
and nuts on the coil support bracket at the
enough to cover exposed area
end plate and baffle plate. Before removal
of coil, ensure the piping connections at
header are disconnected. In case where
two coils are stacking, remove the drip
pan and join brackets which holding the
two coils together.
For DX coils, it is advisable that the
Figure 31 – Side view of Return duct to be large
enough to cover exposed area
refrigerant is to be pumped into the
condenser. If this is not possible,
refrigerant shall be purged out.
IMPORTANT
Top roof are not intended for
people to step on.

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 WARNING Fan array is available for EC plug fan.
DO NOT HEAT ANY PART ON DX Ensure all fans are control to run
COIL IF REFRIGERANT STILL IN THE simultaneously and with same speed.
SYSTEM. HEATING UP WILL CAUSE Fans running at unequal speeds can result
DANGER OF HIGH PRESSURE INSIDE uneven airflow that cause performance,
THE COILS. sound, vibration problems that lead to
failure.
6. Commissioning and Operation
In case one of the fan is down, blank off
6.1 Pre-run Check plate shall be temporarily installed on the
nonfunctional fan to prevent air re-
6.1.1 Preparation circulation while waiting fan replacement
(See Figure 32). If present of differential
The complete air handling unit and all pressure controller, ensure the pressure
accessory components should be tube of nonfunctional fan is capped and
thoroughly cleaned and all dust & debris amend the setting of controller accordingly.
completely removed.
Make sure that all transport brackets and
packing have been removed.
Ensure all screws, bolts and nuts on AHU
are secured tightly (not loose during AHU
transportation or handling).
Ensure all panel and belt drive settings are
secured due to change during shipment or
installation.
In case additional equipment is installed at
site, ensure air leaking spots are being
seal with additional baffle plates or seal
with silicone to prevent air bypassing.

WARNING Figure 32 - Fan Array with Blank-off Plate

ISOLATE THE ELECTRICAL &
MECHANICAL ENERGY SOURCE AND 6.1.4 Vibration Isolator Mount
PADLOCK THE SWITCH BEFORE Ensure the vibration isolator mounts and
SERVICING THE FANS AND MOTORS. flexible connections allow the fan and
6.1.2 Fan / Motor motor to move freely without constrain.
For the fan with Restrained Spring Isolator,
Make sure the fan impeller can rotate ensure that the Alu Angle plates are
freely by hand. Check the tension and removed from the restrained spring
alignment of the belt drive. isolator before commissioning.
Check motor connections and make sure
correct voltage is supplied. If standby IMPORTANT
motor is available, make sure only one
The clearance between flanges of
motor to power source.
Seal end of fan motor conduit (if “Top plate” and “Base plate” for
applicable) and the motor terminal box restrained spring isolator should
with silicon sealant. be approximately 10-20mm.
VFD/Frequency Inverter for TEFC motor
can only vary the frequency within 30 to 6.1.5 Coils
60 Hz in order to control the motor
Check the pipe-work to coil is correctly
rotation speed. For VFD setup, make sure
connected and the fins are free from
the VFD settings according to
foreign matter or damage.
recommendations at VFD manual.
Check that the condensate drain is trap.
When multiple fan with multiple VFDs,
Ensure good sealing of silicon around the
fans must set up to always start
coil headers and drain pipe.
simultaneously and with same speed.
6.1.6 Damper & Filters
6.1.3 Fan Array

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Check all dampers are operating correctly
as per design.
Make sure all filter media are installed in
correct airflow direction.

6.1.7 Panel & Section

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

6.1.8 Electric Heater

Figure 34 - Wiring Diagram with Neutral
Electric Heater – Before starting-up,
ensure that the air flow through the Heat Wheel – Ensure the heat wheel can
heater should not be lower than 2.0 m/s rotate freely by hand.
to avoid overheating heater. Heat Pipe – Ensure installations are as per
manufacturer recommendation.
WARNING
FOR 380-415V/3PH, STAR 6.2 Start-up Check
CONNECTION WITHOUT NEUTRAL Competent, well-trained personnel must
(Figure 33), UNBALANCED PHASE be employed in the following operations to
VOLTAGE MAY CAUSE DAMAGE ON ensure Safety Rules and Regulation being
THE ELECTRIC HEATER. adhered to at all time.

IMPORTANT
FAILURE TO PROVIDE MOTOR
OVERLOAD PROTECTION COULD
RESULT IN MOTOR DAMAGE.
CONNECT THE MOTOR TO AN
OVERLOAD PROTECTIVE DEVICE
THAT IS RATED IN COMPLIANCE
WITH THE APPLICABLE CODE.
a. Check the rotation of the fan impeller.
Figure 33 - Wiring Diagram without Neutral
If the fan rotates in opposite direction
from desire, reverse any two phase
FOR 380-415V/3PH, STAR
connection at motor terminal.
CONNECTION WITH NEUTRAL
b. Check that there is no unusual noise
(Figure 34), NEUTRAL POINT MUST
or vibration. Stop and investigate if
BE CONNECTED IN ACCORDANCE
found. (refer to section 8)
WITH WIRING DIARGRAM IN ORDER
c. Measure the voltage and drawn
TO CARRY CURRENT DUE TO current of the motor. The drawn
UNBALANCED PHASE VOLTAGE. current must not exceed the full load
current mentioned at motor
IMPORTANT
nameplate.
SAFETY THERMOSTAT IS FOR
OVERHEATING PROTECTION ONLY, 6.3 After first 48 hours of operation
NOT FOR CONTROL PURPOSE.
DEFAULT SETPOINT IS 60˚C. a. Make sure complete isolate the
IT MUST BE CONNECTED TO Electrical source.
CONTACTOR (WHETHER SUPPLIED b. Re-check and Re-tension the drive
BY FACTORY OR SITE) TO CUT-OFF belts due to stretch.
HEATER IN CASE OF OVERHEATING c. Check and adjust the pulley alignment
HEATER. to ensure the motor fixing is properly
secure.
d. Check all bearing, wheel bolts & nuts
and sheave set screws (or cap screw)
are in secure position.

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 CAUTION Check that vibration isolator mounts are
HIGH AIR TEMPERATURE IN FAN functioning well.
SECTION CAN CAUSE MOTOR Inspect for any obstructions or blockages
at air intakes and discharges.
OVERHEAT AND DAMAGE. ON
Check fan bearings are secured and no
DRAW-THROUGH AIR HANDLERS,
undue noise by observe/listen using metal
ADJUST THE DISCHARGE AIR
bar as a conductor.
TEMPERATURE OF THE HEATING
If unit equipped with belt guard, check
SECTION NOT TO EXCEED 1040F
that it is fitted correctly and secure.
(400C). If there is any undue noise or knocking
6.4 Fan Operating Limits from bearing, replace both bearings. Fan
bearing are grease for life, but larger units
The fan operating limits for forward curve with standard bearing require semi-annual
and airfoil fan are shown on the Table 3. or annual lubrication at bearing greasing
Total static pressure should be limited to nipple. Recommended lubricants are
1000 Pa for forward curve and 1500 Pa for Standard Din 51823, K3N or ISO XM2.
backward curve/airfoil fan.
Table 3 - Fan Operating limits 7.2 Drive Belt
Backward
Forward Curved Belts that are split or have frayed edges or
Blower Curve/Airfoil
Size Max. Max. Max. Max. any other sign of damage (rubber shred
RPM kW RPM kW on floor) must be replaced in full set.
200 3800 3 5700 2
225 3400 4 5400 3
250 2600 4 4400 3 IMPORTANT
280 2400 6 3900 4 DURING MAINTENANCE AND
315 2100 6 3500 5 SERVICING, UNIT MUST BE
355 1900 8 3100 6
400 1700 8 2700 8
COMPLETELY ISOLATED AND
450 1400 10 2500 11 PRECAUTIONS TAKEN TO PREVENT
500 1200 11 2200 11 ACCIDENT FROM HAPPENING.
560 1100 15 1900 15
630 900 15 1700 15 Check the belt tension and alignment, re-
710 850 25 1500 30 tension and re-align if necessary. Refer to
800 750 25 1350 30
900 650 30 1150 35
Section 5.7 for belt tensioning procedure.
1000 600 30 1050 35 New belt drive must be re-tensioned after
the first 48 hours of operation.
6.5 Installation of VRV AHU Control For replacement of belts, remove the belt
Box (EKEQ) guard before starting work. To change the
belts, first loosen the adjusting screw and
For installation VRV AHU Control Box,
move the motor towards the fan to enable
please refer to the Installation And
old belts to be taken off and put on of
Operation Manual in VRV ED or refer to
new belts. (Matched belts must be used)
manufacturer for advices.
Tension the belts by following instruction
6.6 MicroTech III Commissioning at Section 5.7.
MicroTech III is an option. For
7.3 Coil Section
commissioning of MicroTech III, please
refer to the MicroTech III Commissioning Periodic cleaning of coils is required. Dirty
Manual in VRV ED or refer to coils have tendency to increase airside
manufacturer for advices. pressure drops and reduce cooling/heating
efficiency. Dry cleaning is done by using a
7. Maintenance powerful vacuum cleaner on the dust-
accumulated side. If coil is very dirty, coils
7.1 Fan / Motor need to be removed for wet cleaning by
Check for soiling, corrosion, damage and trained personnel. Ensure coil fins are not
tendency of excessive vibration. damage when performing dry/wet
Check that all bolts and nuts and flexible cleaning. In the event that fin edges have
connections are securely fixed. been bent, treat with aid of a coil comb.

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 Check that frost protection is working 7.4 Filter Section
before starting of each winter season.
During system start up, filters are likely to
Ensure the frost sensor is correctly
become rapidly blocked.
installed and working within desired
temperature range. Disposable filters and bag filters must be
For direct expansion coils, do not use hot replaced each time when pressure drop
water or steam to clean these coils. During reaches the indicated dirty condition by
normal operation, the fin block must not D.M. Manometer. Washable filters must be
be ice up. If this occurs, check the cleaned periodically.
refrigeration system.
7.5 Dampers
Check that drain pan and drain trap are
free from blockage and water Check for dirt accumulation, damage and
accumulation at pan. sign of corrosion. Clean with cloth or high
pressure air. Check damper blade turning
manually or central control for smooth
operation.
Table 4 - Recommended Maintenance intervals
Maintenance interval
Component Description Action
Weekly Monthly 3 Monthly 6 Monthly Yearly

Fan / Motor Fan in general Check / Clean ●

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

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7.6 Electric Heater 7.8 Moisture Eliminator
Check for dirt accumulation and clean if Check the dirt accumulation at the blades,
necessary with a soft brush. Check the remove and clean the blades if necessary.
safety control, cables and connections Ensure the blades are correctly positioned
operation. and not distorted.

IMPORTANT 7.9 Maintenance Plan for Air

AIR VELOCITY SHOULD NOT BE Handling Units
LOWER THAN 2.0 m/s. The schedule provided in Table 4 gives
recommended maintenance intervals for
7.7 Heat Wheel & Heat Pipe
the AHU unit (Guideline only).
The unit should be maintained in line with Intervals are based upon normal running
the manufacturer recommendation. Please conditions, in a moderate climate and
refer installation and maintenance manual assuming 12-hour running. Units operating
for details. outside these guidelines may require
shorter or longer maintenance intervals.

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

Table 5 - Trouble shooting analysis

Symptom Probable Cause Recommended Action
Motor fail to start a) Blown fuse or open circuit breaker. a) Replace fuse or reset circuit breaker.
b) Improper wiring. b) Check wiring with diagram supplied.
c) Mechanical Failure. c) Check motor & drive rotate freely &
bearing lubricant.
Motor stall a) Short circuit or phase to earth. a) Check line phases and terminal block
b) Overload motor. connection.
c) Low line voltage. b) Reduce system load.
d) Over tensioned belts. c) Check supplied voltage within motor
e) Misalign drive. voltage range.
d) Adjust belt tension.
e) Re-align drive.
Motor overheats a) Overloaded motor. a) Reduce load or replace larger motor.
b) Motor Fan dirty/ damage. b) Clean/ replace motor fan.
Low air volume after a) Fan rotating in wrong direction. a) Reverse any two phase connection at
start up b) Air damper not properly set. motor terminal.
c) Pressure drop by filter above b) Ensure system correctly balance & set.
recommended level. c) Change filters – (complete bank).
Excessive motor noise a) Motor mounting bolt loosen. a) Tighten motor mounting bolt.
b) Worn motor bearing. b) Replace bearing and seals.
Excessive noise from a) Worn fan or motor bearing. a) Replace bearing and seals.
unit b) Fan impeller rubbing on inlet cone or b) Check clearance or remove for repair.
cover. c) Check tension.
c) Incorrect drive belts tension.
Excessive vibration a) Fan impeller out of balance. a) Consult manufacturer.
b) Transport bracket not remove. b) Remove transport bracket.
c) Improper pulley alignment. c) Check pulley alignment.
d) Over-tensioned belts. d) Re-tension belts.
e) Vibration isolator damaged. e) Replace vibration isolator.
f) Motor shaft bend. f) Send the motor for repair.
g) Bad bearings. g) Replace bearing and seals.
h) Loosen bearing hold down bolt h) Tighten hold down bolt.
i) Fan & motor section not evenly i) Re-adjust and tighten.
supported on foundation. j) Conducts dynamic balancing.
j) Fan assembly’s tolerance is out of
range.
Bearing excessively hot a) Over-tensioned belts. a) Re-tension belts.
b) No lubricant. b) Apply lubricant

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 c) Over-lubricant. c) Purge and clean surface.
d) Misaligned bearing. d) Check & re-align shaft.
Water present in cooling a) Drain trap clog. a) Clean & clear clog.
coil drain pan or overflow b) Incorrect hydraulic trapping. b) Resize trap and check air break
arrangement.
Premature drive belts a) Improper tension or alignment. a) Check tension and alignment.
failure b) Incorrect belt being fitted. b) Replace with full set.
c) Dirt or grease on belts. c) Clean belt & pulley, check for grease
d) Belt rubbing. leak.
e) Worn sheaves. d) Remove obstruction.
e) Replace sheaves.
Belt swelling or softening a) Excessive contamination by oil, certain a) Replace with full set. Isolate the source
cutting fluids or rubber solvent. of contaminate.
Belt whipping during a) Incorrect tensioning. a) Re-tension belts.
running
Filter collapsing a) Filter block with dirt. a) Replace at advised dirty condition.
b) Air velocity too high. b) Check unit running conditions.
Note: The table is intended as a diagnostic aid.

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

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