Operational Manual of Air Handling Unit

OPERATIONAL MANUAL

AIR HANDLING UNIT

(Direct expansion cooling)

MAKER : DM ALSCOTT MARINE OFFSHORE HVAC LTD.

Version : 1101

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DMA reserves the right to change design or specification without prior notice.
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 Operational Manual of Air Handling Unit

Table Of Contents

1. Product introduction of standard AHU . 3

2. Structure of standard AHU .. .. 4

3. Receiving and storage . . 5

4. Rigging and handling . .... .. 6

5. Unit installation . .. 7

6. Damper . ... .. 9

7. Filter . .. 10

8. Heater . . ... 11

9. Cooling coil . 13
10. Centrifugal fan and motor ... . . . 14
11. Special caution Draining water for coils during frozen environment.... 16

Note!
The instruction must be followed to ensure safe, proper operation
and maintenance of Air Handling Unit.
It shall be brought to the attention of anyone who operates or
maintains this system.
Ignoring the instruction may invalidate the warranty.

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 Operational Manual of Air Handling Unit

1. Product introduction of standard AHU

Description

MAHK marine air handling unit is the important device to deal with the temperature and humidity of
the air in the cabin.
Normal AHU parts consist of the following sections, which can be freely combined and mounted in
casings to form complete sections: mixing air intake, filter section, heating section, cooling section,
humidifying section, droplet separator section, fan section, discharge section.

Features

l Packaged framework and panels are main and special structure for the unit.
l The panels are 50 mm thick and consist of a double skinned steel sheet with intermediate
mineral wool. Al-Zinc steel or Stainless Steel is available for panel material.
l Good acoustic and thermal insulation for the unit.
l Hard fastness between panels and frame to ensure good air tightness.
l The spiroduct air pipe can be connected directly to the sections for easy installation.
l The access doors are available, which can be opened and detached easily for inspection and
servicing.
l The functional sections are optional for customers, and meet the most demanding
requirements.

Fig. 1 Standard Air Handling Unit

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2. Structure of standard AHU

Fig. 2 Standard sections of Air Handling Unit

Standard AHU comprises of following sections:

l 1. Mixing section
l 2. Filter section
l 3. Heating section
l 4. Cooling section
l 5. Humidifying section
l 6. Droplet separator section
l 7. Fan section
l 8. Air discharge section

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3. Receiving and storage

Receiving

Inspection upon receiving, check the following points, and notify the supplier for any discrepancy
Is there any damage for the unit Such as panel, junction box, damper, inlet/ outlet connection
for air duct, refrigerant, and heating medium etc.
Are the nameplate identical with what you ordered
Are the items received against packing list identical with what you ordered
Are dimensions of AHU in compliance with your specifications
If there are any specific requirements, please ensure they are in conformity you re your
specification.

Storage
When AHU are not ready for storage, the following precautionary measures shall be undertaken
to ensure best position and performance.

3.1. Place
High and dry well ventilated without direct sun, dust or corrosive gas.
Entirely free from strong vibration and easy for movements.

3.2. Well protection

AHU shall be well shielded from dust, but under well ventilated circumstances.

3.3. Long period storage

If the unit is not in operation for a long period (one week and above) after installation or has been
in operation but stopped for a period of time, the following precautions must be taken:
Store unit in a clean, dry place and protect it from weather and construction traffic.
The storage site shall be level, rigid, and free of debris. If the site is in a heavy rain area, set the
unit off of the ground.
Ensure that all coil connections have shipping caps in place. Cover the entire unit with a
waterproof tarpaulin or plastic coverall. if the unit is stored on the ground, extend the cover
underneath the unit. Secure the cover with tie downs. Do not remove cover or coil end caps until
unit is ready for final installation.
Monthly -- Move the cover all, enter the fan section through the access door or fan inlet, and
slowly rotate the fan and motor by hand. This operation prevents bearing corrosion by
redistributing the bearing grease.

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 Operational Manual of Air Handling Unit

4. Rigging and handling

Fig. 3 Sketch of rigging and lifting AHU

Rigging and handling

To transfer the unit from the shipping platform to the storage or installation site, refer to the
following points and above Fig. 3.

4.1. Weight
The weight and dimension of AHU are indicated on the sketch drawing of working file.

4.2. Sling
Usually, the length of sling, 4~5m, is recommended (or per site condition).

4.3. Protection
Suitable sling is chosen to lift the unit. During the hoist, some necessary measures shall be
applied to protect the unit and its components or extended parts, such as coil s connection,
extension panel, spiroduct outlet, junction box etc.

Note!
A forklift truck can be used to move unit or components only if they have full skids. Lift
from the heavy end of the skid. Sufficient fork length shall be ensured. Failure to follow
these safety precautions could lead to personal injury and/or equipment damage.

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 Operational Manual of Air Handling Unit

5. Unit installation

5.1.Base frame
The common foundation yard made for AHU shall be level strictly. Before the AHU is located on
the site, the foundation has to be aligned to ensure the level and stable of the base frame, so the
four corners of AHU are also level and stable, otherwise AHU s base frame and casing will be
distorted, even effect the open and close of inspection door of AHU.

5.2.Air duct connection

As standard supply, maker will provide the counter
flange (including all bolts and nuts) for duct connection.
The installers just connect the air duct into the counter
flange, and then fix them with rivets.
As additional supply, for the case with the flexible
connection provided, just install the flexible connection
between the AHU s damper and air duct.

counter flange

Fig. 4
5.3. Cable connection
For the cable installation of fan motor, electric heater,
etc., cable inside the AHU shall be fixed along the
cable bracket, then lead to the cable gland. Remind
that the installation of cable shall not interfere with the
service space of the unit. Avoid water entering into the
junction box along the cable.

cable gland

Fig. 5
5.4. Water trap
Water trap (one-way valve) shall be applied to
drain out the condensing water from drip pan of
cooling section in AHU, since the inside pressure
of AHU is minus pressure.
The height of H is decided by the pressure
difference between outside pressure and inside
pressure in AHU. Normally the H is 160mm for
standard supply.
Fig. 6
5.5. Panel
The panels, 50mm thickness, are fixed by hexagonal screw 6.3x20mm (Fig. 7) onto the AHU
case, and the socket spanner 10mm width, concave hexagon, Fig. 8 , shall be used to drive out
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 Operational Manual of Air Handling Unit

the screw and detach the panels.

On the panel, a black plastic plug (Fig.7) is applied to cover the screw hole (diameter 16 mm).
The plug shall be removed before detaching the panel.

Fig. 7 Fig. 8

Panel Spanner
Plug
Screw

Fig. 9 Fig. 10

5.6.Door
As to the inspection door of AHU, the fixed side of door is connected with hinges fastened on the
AHU case, and the moved side is equipped with locks. The special key shipped with the AHU, is
provided to lock or unlock the door (Fig. 11). The door can be detached by remove the cylindrical
pintle (pintle diameter 8mm) of hinge, see Fig. 12 below.

Fig. 11 Fig. 12

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8. Damper

Multi-leaf dampers, Fig.13, are primarily used in air inlet of AHU for volume flow and pressure
control.

Fig. 13 Fig. 14

Casing and blades made from galvanized rolled sheet steel, and casing flanges with holes in
the corners on both sides.
Blade spindles and external linkage made from galvanized steel.
Plain bearings made from special copper with free charge for lubrication.
Parallel blade operation.
Drive arm may be located on any blade.
Indication label with Open and Close riveted on the handle bracket, see Fig. 14
In general there is very little maintenance to be done.

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 Operational Manual of Air Handling Unit

9. Filter

Panel type filter (Fig. 15, 16)

Frame: Al alloy, or rigid high wet-strength beverage board
Media: Non-woven reinforced cotton & synthetic media.
Media support grid: welded steel wire, anti-corrosive.
Efficiency: G4 (EN 779): 25%-30%, ASHRAE 52/76, >95% @ ( 5um).
Fire retardant grade: UL-2 listed. (UL 900)
Humidity: 100%RH.

Fig. 15 Fig. 16

Pocket type filter (Fig. 17)

Frame: Galvanized sheet metal, 20mm header frame.
Media: Synthetic fiber.
Efficiency: G4 (EN 779): Avg. arrest, 90~95%.
Temperature: 70 .
Humidity: 100%RH.

Change and maintenance

Both panel and pocket filters are disposable and
replaceable.
The changeable interval depends on the content of
dust in the air.
Fig. 17
The filters with metal frame are washable, however we
don t recommend the customer to wash the filter, since
these action will decrease the efficiency of filters. Changing the filters is advised normally.
Note: the metal framework of filter shall be face the downstream of air.

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 Operational Manual of Air Handling Unit

10. Heater

AHU s heater included steam (hot water, oil) heating coil (Fig.18), and electric heating coil
(Fig.19). For the former coils, the tube material is copper or stainless steel, and that of fin is
copper, aluminum, or stainless steel. The electric heating coil comprises of stainless steel tube
and stainless steel fin.

Fig.18 Fig. 19

Installation

During the pipe connection for heating coil, high

attention shall be paid to avoid the distortion and
damaged of the internal pipe since the soldering points
of coil is weak for great rotation (Fig. 20). The extended
pipe shall be hold tightly by tools for connection.

Soldering

Thread
Fig. 20

Maintenance
The maintenance for heating coil in tube / fin type, is same with that of cooling coil, see Section
11.

Anti-freezing thermostat
Anti-freezing thermostat, KP61, is installed at the downstream of heating air, which is for use to
avoid fan running when the temperature of inlet air is very cold.
Normally, the setting point of thermostat is as bellow:

Cut in (reset): 5 , and cut off: 0 .

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 Operational Manual of Air Handling Unit

When the temperature of inlet air after heater is lower than 0 , the thermostat will output off
signal, then the fan will be stopped. And the fan will be start as the temperature reached 5 .

Fig. 21 KP61 on panel

Overheat protection for electric heating coil

Both overheat thermostat and fuser are equipped on electric heating coil (Fig. 22), which are
series-wound together on electric circuit.

Overheat thermostat
and fuser

Fig. 22

For the standard setting of heating coil, the electric heating will be cut off when the temperature of
heating air reaches 75 , and the thermostat will be reset as the temperature is lower than 65 .
If the overheat thermostat is not activated or cannot work, the fuser will be cut off when the
heating air reaches 160 . Then the operator shall replace the fuser later on.

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11. Cooling coil

According to the difference of cooling medium, some cooling coils are for Freon such as R404A,
R407C, R134a etc., others are for cooling water or glycol etc. Normally, the cooling coil is made
from copper tube and aluminum fin, or copper fin (Fig.23).
To protect the capillary avoiding friction during coil working, the black rubber tube is used to cover
the surface of copper capillary (Fig.24).

Fig. 23 Fig. 24

Installation

Same to heating coil, during the pipe connection for cooling coil, high attention shall be also paid
to avoid the distortion and damaged of the internal pipe since the soldering points of coil is weak
for great rotation. The extended pipe shall be hold tightly by tools or hand for soldering connection.
Remember to keep the clear of pipe inside, and don t let any solder, debris etc. jump into the
system pipe.

Maintenance

In general there is very little maintenance to be done. However, this will vary depending on the
site conditions. In areas with heavy air pollution, greater care has to be taken and maintenance
carried out frequently. It is important that the fins are regularly inspected for damages that may
arise or interruptions of work. In case of damages, the maker shall be contacted, and no repair
work shall be done, without maker s instruction.

On the other hand, as to dust on slats, although the filter is satisfactorily cleaned, some dust will
pass through and stick to the slats. This will reduce the capacity of the coil. The cleaning of the
slats may be done by compressed air or steam, or by flushing with water. In case of oily pollution
a suitable detergent can be added. Mechanical cleaning of the slats can be readjusted with a slat
comb.

Again, the maintenance has to be carried out with great caution to avoid damage to the fins.
Usually the droplet separator shall be moved away before maintaining or cleaning the cooling
coil.
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 Operational Manual of Air Handling Unit

12.Centrifugal fan and motor

Start-up checklist for fan

Before putting any fan into initial operation the
manufacturer s instruction must be followed.
Complete the following checklist to make sure that
the fan is ready to run.
1) Lock out the primary and all secondary power
sources.
2) Make sure the foundation or mounting
arrangement and the duct connections are
adequately designed in accordance with
recognized acceptable engineering practices
and with the fan manufacturer s
Fig. 25 Supply fan inside AHU
recommendations.
3) Check and tighten all hold-down (securing) bolts.
4) Check the fan assembly and bearings for proper grounding to prevent static electricity
discharge.
5) Spin impeller to see whether it rotates freely and is not grossly out of balance.
6) Inspect impeller for correct rotation for the fan design.
7) Check belt drive or coupling alignment.
8) Check belt drive for proper pulley selection and make sure they are not reversed.
9) Properly secure all safety guards.
10) Switch on the electrical supply and allow the fan to reach full speed.

Check carefully for:

(1) Excessive vibration
(2) Unusual noise
(3) Proper amperage and voltage values
(4) Proper belt alignment

If any problem is indicated, SWITCH OFF IMMEDIATELY. Lock out the electrical supply, secure
the fan impeller if there is a potential for wind milling. (impeller turning due to a draft through the
system). Check carefully for the cause of the trouble and correct as necessary.

The fan may now be put into operation but during the first 8 hrs of running, it shall be periodically
observed and checked for excessive vibration and noise. Checks shall be made of motor input
current and motor & bearing temperature to ensure that they do not exceed manufacturer s
recommendation. After 8 hrs of operation, the fan shall be shut down to check the following items:
(1) All set screws and hold-down bolts
(2) Belt drive alignment
(3) Belt drive tension
(4) Bearing housing temperature
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After 24 hrs of the satisfactory operation, the fan shall be shut down, and the drive belt tension
shall be readjusted.

Bearing lubrication for fan

Fan equipped with pillow block bearing inserted in rubber damper are pre-lubricated and shall not
require additional grease for start up.

However, for plumber block bearing, with lubrication point can be further lubricated when the life
of grease is expectancy. This will depend on the type of grease, speed and operating
temperature of the bearing. The best way to determine the re-lubrication frequency is to inspect
the condition of the old grease that purges from the seals when adding new grease. If the purges
grease looks just like the new grease, you can go a longer time between re-lubrications. If the
purges grease is much darker than the new grease, this indicates that the grease is oxidized and
you must re-lubricate more frequently.

Routine maintenance for fan

Maintenance shall always be performed by experienced and trained personnel. Do not attempt
any maintenance on a fan unless the electrical supply has been locked out or tagged out and the
impeller has been secured.

Under normal circumstances, handling clean air, the system shall require cleaning only about a
Year. However, the fan and system shall be checked at regular intervals to detect any unusual
accumulation.

The fan impeller shall be specially checked for build-up of material or dirt which may cause an
imbalance with resulting undue wear on bearings and belt drives. A regular maintenance program
shall be established as needed to prevent material build-up.

Periodic inspection of the rotating assembly must be made to detect any indication of weakening
of the rotor because of corrosion, erosion, or metal fatigue.

Motor for fan

Motor s installation and maintenance shall refer to the instruction of motor individually.

Fig. 26 Motor structure

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 Operational Manual of Air Handling Unit

Special caution
(only for steam coil and water coil)

Draining water for coils during frozen environment

!
Please NOTE

Drain the water inside steam coil or water coil when the coil

is standby and the local temperature is lower than 0 .

Ignoring the NOTE may invalidate the warranty of coil.

Coil

Drain valve

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