MODULAR AIR HANDLING UNIT

MC6 SERIES

INSTALLATION, OPERATION AND

MAINTENANCE INSTRUCTION MANUAL

By: MICRONAIRE GLOBAL SDN BHD

1
OVERVIEW
Please read the equipment instruction manual before installing, starting up and servicing the
equipment to ensure the safety running of the unit.

Starting up and servicing the equipment can be hazardous due to the system operating
pressures, electrical components and equipment location. Therefore, only trained and qualified
personal should perform the start-up and servicing of the equipment.

All the installation procedures of the unit must follow the relevant international and country
codes.

When working on the equipment, observe precautions in the literature, and on the label, sticker
attached to the equipment.

Use care in handling, rigging and settling the bulky equipment.

If more information is needed or there is something which is uncovered in the manual, please
contact with MICRONAIRE GLOBAL SDN. BHD.

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Contents
OVERVIEW ............................................................................................................................. 2
1. INTRODUCTION ............................................................................................................... 4
1.1 General ......................................................................................................................... 4
1.2 Operating Environment and Applications ................................................................... 4
1.3 Safety Information ...................................................................................................... 4
INSTRUCTION MANUAL FOR AIR HANDLING UNIT ............................................................ 5
1.4 Construction and Configuration .................................................................................. 5
1.5 Power, Utilities and Cooling Medium.......................................................................... 5
1.6 Transportation, shipment and Acceptance ................................................................. 6
1.6.1 Inspection and Acceptance ........................................................................................ 6
1.6.2 Lifting and Transportation .......................................................................................... 6
1.6.3 Service & Access Clearance ...................................................................................... 8
1.7 Equipment Installation................................................................................................ 8
1.7.1 Installation Platform and Arrangement ....................................................................... 8
1.7.2 Vibration and Noise Isolation ..................................................................................... 9
1.7.3 Refrigeration Pipe Connection ................................................................................... 9
1.7.4 Typical Drain Pipe .................................................................................................... 10
1.7.5 Cable Termination Installation .............................................................................. 10
1.7.6 Section Joint Installation ....................................................................................... 11
1.8 System Operation .................................................................................................... 12
1.8.1 General................................................................................................................. 12
1.8.2 Safety Consideration ............................................................................................ 12
1.8.3 Disposal of parts/materials ................................................................................... 13
1.8.4 Start-Up Instructions ............................................................................................. 13
1.9 MAINTENANCE ....................................................................................................... 18
1.9.1 General................................................................................................................. 18
1.9.2 Maintenance Checklist and Maintenance Intervals ............................................... 18
1.9.3 Maintenance Instructions ...................................................................................... 21

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1. INTRODUCTION

1.1 General
This instruction manual covers the installation of Air Handling Units (AHU). To guarantee safety
during operation, please read through the instructions in this document and alert to the warning
instruction of the product. Any modifications in the design and/or installation of the product
without discussion with manufacturer and without advance written agreement will result in the
loss of the right to any product warranty claims and any claim for injury to personnel because
of these modifications. Read the product catalogue and instruction manual of the components
and catalogue for information, which model and specification shall according to design drawing
and data sheet. Maintenance procedures may only be carried out by qualified personnel.
Cooling elements are manufactured and supplied in accordance with guidelines of the Pressure
Equipment Directive (PED). Same maintenance shall apply to ventilation fan according to the
available parts or components in design drawing and data sheet.

1.2 Operating Environment and Applications

Air Handling Unit functions and operates for the air quality, air movement and air conditioning,
unless otherwise specified in design drawing and data sheet. This manual provides operation
guidance of general components. Operating environment and actual components for the
system shall according to equipment specification and data sheet.

1.3 Safety Information

The following safety descriptions are used in this manual. Read and follow all safety instructions
in this manual precisely to avoid unsafe operating conditions, fire, explosion, property damage,
personal injury, or death. Keep this manual for future reference.
• Danger statements are descriptions of an imminent hazard that will result in
severe injury or death if not avoided and should be limited to the most extreme
situations.
• Warning statements are descriptions of a potentially hazardous situation which if not
avoided could result in minor personal injury or serious injury or death.
• Caution statements are descriptions of a potentially hazardous situation which if not
avoided could result in minor or moderate personal injury.

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INSTRUCTION MANUAL FOR AIR HANDLING UNIT

1.4 Construction and Configuration

Standard Air Handling Unit is constructed with mixing box, filter section, cooling coil section,
and ventilation fan section within enclosure. As optional, Air Handling Unit may also have
constructed with electrical heater section, humidifier section, heat recovery section and others
according to equipment data sheet. Standard MAC MC6 Series shall include following unit
construction,
• Common skid/ individual skid for modular unit.
• Aluminium frame with thermal insulation and thermal break nylon design.
• Double skinned enclosure panel with thermal insulation.
• Thermal insulated drain pan and drainage.
• Mounting frame for fan and motor with vibration isolator and flexible duct connection.
• Maintenance access door for components within the enclosure.

Air handling unit are customized equipment according to system design requirement. Actual
equipment configuration and specification shall refer to equipment data sheet and arrangement
drawing.

1.5 Power, Utilities and Cooling Medium

Parts, components and accessories within the equipment are designed according to the
available power and utilities. Operator shall understand the following details of the equipment
before equipment start up.
- Refrigerant (For DX Coil): R404a, R407c, R134a, R417a or others
- Chilled Water (For Chilled Water Coil)
- Power Supply for Low Voltage or Extra Low Voltage Electrical Components and
Instrument.

! Caution: Electrical power supply must according to the equipment name plates / data
sheet.
! Caution: Using different refrigerant from design may causing damage to the system
may causing damage. If it is essential, please send enquiry to Micronaire Global Sdn.
Bhd.

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1.6 Transportation, shipment and Acceptance
1.6.1 Inspection and Acceptance
Following procedure shall be followed upon receiving of equipment.
• Users should check up the whole package unit completely on its arrival
• Check the equipment packing with the bills of lading
• Checkout whether the model and electric parameter on the label accord with the unit
• Inspect if there are damages caused when transport. Check spare parts with packing
lists and write down the problems on the transportation document and send a claim
for compensation to the transportation company.

1.6.2 Lifting and Transportation

Each unit shall be inspected strictly. Therefore, the removal persons should ensure the
following items besides hoisting or handling with care
Horizontal Transportation
• Roller with adequate number shall be place underneath the unit
• Ensure the roller position to balance the weight
• Ensure the pathway is flat and without obstruction
• Slowly push the unit to the designated area

Figure 1: Horizontal Transportation

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Vertical lifting
• Hoisting belt should be firm;
• The belt shall wrap the base from 1 side to another side.
• Steel bar shall apply at 4 sides of the belt to avoid tension damage to the unit
• Lift and put carefully with crane according to hoisting scheme of unit delivery. Ensure
to lift the unit slowly and steadily. Do not lift or handle the unit savagely.
• Forbid anything deposited on top of the plant, be careful to avoid damaging the unit.
• The length of the belt/chain shall adjust adequately to avoid imbalance of the lifting

Figure 2: Vertical Lifting

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 1.6.3 Service & Access Clearance

Figure 3: Minimum Clearance for Service & Access

1.7 Equipment Installation

1.7.1 Installation Platform and Arrangement
Equipment should be installed on concrete raised floor or foundation skid, which should be flat
with enough intensity and stiffness. Put sufficient strengthen beams to enhance the plates of
the bases and alignment with rubber pad below the equipment skid.
Following space requirements are recommended for installation layout,
- Space above unit should not be less than 1 meter;
- Keep 750mm length passage path at both side of side of the unit;
- Operation space not less than 1 meter when face the operating panel (electric box side).

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 1.7.2 Vibration and Noise Isolation
Shake proof isolation device should be considered for equipment installation. Rubber pads or
spring absorbers installation between the base of plant and structure base are recommended.
Even if not use absorbers, flexible connection is recommended to be installed in the inlet and
outlet water pipes of the unit when install the cooling water pipes because metal expands with
heat and contracts with cold.
! Caution: Must select absorbers which resist cutting when using spring vibration
isolators;
! Caution: Must select flexible connection pipes or one (1) meter long soft pipe, which
is corresponding with the liquid, pressure and flow going through them for DX
system.

Figure 4: Rubber pad shall be placed underneath of the unit

1.7.3 Refrigeration Pipe Connection

If it is DX type AHU, the refrigeration pipe connection must be installed and fixed with pipe
clamp and support bracket.
- Connection shall be installed according to the schematic diagram;
- Ensure the lubricant oil can return to compressor continuously, avoid the oil lack of
compressor.
- Set necessary suction rising and oil returning bend to avoid liquid overflowing of
compressor.

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 1.7.4 Typical Drain Pipe
There must have proper trap in drain pipe system (U-trap/Ball trap). Following schematic
diagram shows the guidance of drain pipe design and installation.

Figure 5: Drain Pipe Schematic Diagram

Notes: Water trap to be supplied by installer and shall be installed at site unless
specified in supply scope.

1.7.5 Cable Termination Installation

Please note the following instructions when connecting electrical cables for the unit:
- All connection should be in accordance with the relevant rules on electric. Find out the
maximum current from the electric data of the unit;
- Inspect whether wires are broken, and the connection is firm. Must use copper wires,
select the section of the wires according to the maximum running current of the unit, the
methods of laying and the distance;
- Connection must accord with the voltage, phase and frequency list in the name plate.
Supply voltage shall change between +6%~ -10%. Unbalance of phase voltage shall not
more than 2% when the unit is working;
- Three-phase sequence must be L1, L2 and L3. Must inspect phase sequence after
connection.
- For additional electrical components/instruments according to design drawing and data
sheet, shall refer to its data sheet and installation instruction

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 1.7.6 Section Joint Installation

If the unit is delivered in multiple section, section joint procedure shall be followed to connection
two or few section together. Below 5 steps procedure to install the section joint accessories.

! Caution: The section joint shall be properly installed to avoid leakage of air and
condensation.

Step 1: Ensure the unit is aligned & levelled

Step 2: Move the unit together close & tight

Step 3: Tighten the bolt & nut to the L bracket

Step 4: Fill up the pre-cut PE foam

Step 5: Screw the section joint cover plate

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 1.8 System Operation

1.8.1 General

Inspect and verify evaporator pipe connection & the electric wire connection are in good
condition, adjust the air flow, water flow or refrigerant flow to meet the design air condition in
room.
Notes: Adjustment shall be done according to available components in system
design.
! Caution: For DX system, professional engineer/technician should be present when
start up the compressor at the first time.

1.8.2 Safety Consideration

a. Lifting Point
Equipment and components must be lifted according to instruction. Any special considerations
prior to the unit/components installation shall be followed.

b. Earth Connection
Equipment must be earthed diagonally at base frame.
- The electrical components in the equipment must be earthed, except for components with
double insulation and/or components with a supply voltage below 50 V.
- The electrical components must be installed in accordance with national and local regulations.

c. Rotating / Moving Parts

There may be rotating/moving parts behind access cover, door or panel which may cause injury
to personal.

d. Electrical Components
There are electrical components behind access cover, door or panel that may be dangerous
for the user/installer. Power supply shall be isolated prior of installation.
! Caution: Only qualified personnel is permitted to carry out work on these components.

e. Shipping and maintenance support/brackets

The temporary support brackets for transportation and maintenance must be removed before
the equipment is started up.
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 f. Air Flow and Pressure
There may be pressurization or moving air during operation. Please take note that the fan must
have been switched off and de-energized for a minimum of two minutes before the door or
access cover is opened.
! WARNING!
Before opening doors, switch off and de-energize the fan, and ensure that it has stopped
rotating. (Minimum of 2 minutes).
! Caution: All doors and access covers must be closed before starting up the Air
Handling Unit or Cabinet Fan.

1.8.3 Disposal of parts/materials

Packaging material and replaced parts/components must be disposed in a responsible manner

and accordance with local regulations.

1.8.4 Start-Up Instructions

Table 2.1 shows the components check list which shall be checked before starting up.
Components and instruments may vary shall be according to design.

FUNCTION COMPONENTS CHECK POINTS

Casing (Indoor
Internal and external panels
installation)
No contamination and
Internal panels damage
Casing (Outdoor
installation) External panels
No crack at joints
Hinges Operation of hinges and
locks in good condition.
Locks Fasten and alignment if
Doors/access cover required
Door seal No Cracks
Flexible connections No Cracks
Outdoor air intake Louvre/cowl No blockages

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 Floor, Condensate drain pan (if
used for filter) No contamination
Droplet eliminator (if used)
Panel filter Filter and sealing in good
condition, Pressure drop
Bag filter across filter
Filters
Pressure Differential Gauge
Operation in good
Pressure Differential Switch / condition
Transmitters
No contamination, No
Evaporator coil
Leakage
Cooler
No contamination, No
Condensate pan
Leakage
No wear, Period
Bearings maintenance for
lubrication
Impeller No contamination
No wear, Period
Motor maintenance for
lubrication
Fan
No wear, Pulley is aligned
Drive (Pulley & Belt) and Belt tension in
operating range
Vibration Dampers Fixing in position
Flexible Connections No Cracks
Pressure Differential Switch / Operation in good
Transmitters condition
No physical damage.
Manual Damper / Non Return
Open/Close operation in
Damper
good condition
Damper
No physical damage.
Motorized / Modulating Damper Open/Close operation in
good condition

TABLE 2.1: START-UP CHECK LIST

! Caution: Equipment start up procedures may only be carried out by qualified and
trained personnel.

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! Caution: Before starting up, ensure that the components have the correct connection
voltage and earth in accordance with the regulations. The doors and access covers must
be closed.
! Caution: Shall not entry the equipment alone for the inspection; one person shall
always stand by at the access door entrance.
! Caution: Shall ensure there is no foreign object is left within the enclosure. It may
damage the component during operation.
a. Enclosure Casing

Tag plate shows the equipment data, which is usually located on the access cover or door of
the fan compartment.
i. Casing panel
- Check the AHU panels for any damage. Any dirt or stains must be removed from
the surface to prevent possible long-term damage. Building debris left on the roof
must be removed. Dirt can be removed with water and a mild household soap
solution. Damage can be repaired by thoroughly cleaning the affected surface,
then treat and paint as necessary. If applicable check the sealing joints and repair
if required.
ii. Access Door/Hatch
- Check the operation of door handles, locks and movement of the hinges. Fasten
and alignment on door handle latch if required.
iii. Flexible Connection
- Check that all flexible connections are attached properly. If necessary, tighten
loose screws.
iv. Earth Connection
- Ensure that the equipment and components have been earthed correctly and in
accordance with local regulations.
v. Enclosure construction
- All panels and frame must be rigid after installation. For outdoor installation, the
roof panel must be installed on the roof and sealed.

b. Air filter
- Check if the filters have been installed correctly.
- Filters may be supplied separately to prevent contamination during transportation and
start-up. Install the filters only after the unit has been cleaned.
- Set pressure switches or filter indicators (if available)
- Close the inspection door.
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 c. Cooling Coil
- Check the connections in accordance with the dimensional drawing.
- Check the connections for leaks.
- Check drain trap is installed.
- Check if fins have been bent during transportation. Comb and straighten the fins.
- After several days of cooling operation check the condensate drain.

d. Fan Blower and Motor

- Remove the transportation and shipment brackets/ wooden blocks between panel and
fan base.
- Check if the fan impeller/ pulley and belts can move or rotate freely without obstructing
the frame, flexible connection or wiring.
- Check the motor connection voltage.
- Check and/or connect the motor in accordance with local instructions and the data sheet.
- Check the direction of impeller rotation. The direction is indicated on the casing by an
arrow.
- Measure the current of the electric motor for each phase. Current must be less the same
and agree with the data on the name plate. Set the motor protection device to the
nominal value.
- Check if the flexible connection is correctly installed.
- Check the pressure switch and set the correct pressure (If available).
- Check the operation of the main control switch.
! WARNING!
Before opening doors, switch off and re-energize the fan, and ensure that it has
stopped rotating. (Minimum of 2 minutes)
! Caution: While working on the fan, the switch has to be locked open.
! Caution: The air flow may cause stationary parts to move (even a fan that is switched
off)!
! Caution: Doors and access covers must always be closed before starting the unit.

e. Pulley and Belt Drive

- Check the pulley alignment by using a straight bar on pulley side plan.
- Groove of pulley must be cleaned.
- Apply belts, loosening the tensioning system to avoid an excessive extension of the
belts and eventual damage. Belt tensioning should be checked with belt tension
gauge. Suitable belt tensioning may according to following table.

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TABLE 2.2: BELT TENSIONING TABLE

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 1.9 MAINTENANCE
1.9.1 General
Regular inspection not only protects the air conditioning system better than the service work
after the air conditioning system goes wrong, but also helps to exhibit the top efficiency the air
conditioning system can display.
! Caution: Equipment maintenance procedures may only be carried out by qualified and
trained personnel.
! Caution: Shall not entry the equipment alone for the maintenance; one person shall
always stand by at the access door entrance.

1.9.2 Maintenance Checklist and Maintenance Intervals

The checklist contains a general overview of the planning that facilitates the inspections and
maintenance. On the following pages there is a more detailed description of the individual
components.

3 months
6months

Remarks
1 month
CHECK

months
FUNCTION COMPONENTS

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POINTS

Casing (Indoor
Internal and external panels
installation) No
contamination
Internal panels
and damage
Casing (Outdoor
installation) External panels No crack at
joints
Hinges Operation of
hinges and
locks in good
condition.
Locks Fasten and
Doors/access covers
alignment if
required
Door seal No cracks
Flexible connections No cracks
Louvre/cowl No blockages *
Floor, condensate pan (if
Outdoor air intake No *
used) under filter
contamination
Droplet eliminator (if used) *

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 Filter and
sealing in good
condition,
Panel filter and Bag filter Pressure drop
across filter
Filters Dirty Filter
*
Replacement
Pressure Differential Gauge
Operation in
Pressure Differential good condition
Switches / Transmitters
No
contamination, *
Evaporator coil Coil cleaning
No leakage
Cooler
No
contamination,
Condensate pan *
Drain pan
cleaning
No wear,
Period
Bearings *
maintenance
for lubrication
No
contamination,
Impeller *
Impeller
Cleaning
Fan No wear,
Period
Motor *
maintenance
for lubrication
No wear,
Pulley is
aligned and
Drive (Pulley & Belt)
Belt tension in
operating
range

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 New belt
replacement
Fixing in
Vibration Dampers
position
Flexible Connections No Cracks
Pressure Differential Operation in
Switches / Transmitters good condition
No physical
damage.
Manual Damper / Non-
Open/Close *
Return Damper
operation in
good condition
Damper
No physical
damage.
Motorized / Modulating
Open/Close *
Damper
operation in
good condition
Notes: * Interval may be depending on manufacturer standard and degree of
contamination.
TABLE 2.3: CHECK POINTS AND MAINTENANCE INTERVAL
! WARNING!
Re-energize all components and to ensure that the fan has stopped rotating before the
doors and access covers are opened for inspection and maintenance.

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 1.9.3 Maintenance Instructions

a. Casing Panel

i. Indoor installation
• Internal inspection for double-skin panels casing and of all dry parts.
• Remove contamination with water and a mild household soap solution.
• If damage to the paint treatment has occurred, remove the rust (if necessary), and
touch up with good quality anticorrosive primer and paint. The outside air intake
sections can show signs of corrosion as they contain wet parts and are affected by
mist, rain and air pollutants.

ii. Outdoor installation

• Check the sealed joints of installed outside and if required seal again with a UV-
resistant and paintable kit.
• Perform same instructions for indoor installation.

b. Door and Access Cover

• Check locks and hinges of all doors and access covers. Fasten and alignment on
door handle latch if required.

c. Flexible Connection

• Check the flexible connections. Repair/replace if any damage.

d. Earthing Connection

• Ensure no damage/missing on earthing connection. Repair/replace if any damage.

e. Fresh air intake

• Observe the contamination of fresh air intake and the maintenance interval.
• Clean the surface that expose to outdoor area/ fresh air intake and repair if any
damage.
Notes: Cleaning must be done to prevent permanent damage to the structure/
component parts which is unable to be replaced.

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 f. Filter

• Filters must be checked once a month for excess pollution, pressure loss, damage
and installation of the slide-in/ front insert/ back insert filters & frames.
• With slide-in filters ensure that the filters have been correctly positioned with no gap
between the wall/frame and among the filter casing.
• When replacing built-in filters, check the gasket/seal and that the filter holding
latches/clips have been correctly installed.
• Filters must be replaced at the required intervals. The timing of the replacement
depends on the type of filter, quality and the degree of contamination of the air.
• The pressure loss across the contaminated filter can be measured with pressure
differential gauge / transmitters. If measurement instrument is not provided in design,
filter cleaning/ replacement shall be done every year.
g. Evaporating Cooler and Drain Pan

• Check once a year for contamination and if necessary clean with compressed air
against the direction of the air flow or clean with a vacuum cleaner.
• Check for connection leakage especially on brazing parts.
• Check the condensate pan for contamination and clean if necessary.

h. Fan Blower

• Fan impeller should be cleaned for better air quality.

• Fan types, brands may be various according to design. Fan blower maintenance for
the operation shall according to fan manufacturer instruction.

i. Motor

• Motor bearing types are specified in the respective product catalogs and on the
rating plate of all motors except smaller frame sizes.
• Motor types, brands may be various according to design. Motor maintenance for the
operation shall according to fan manufacturer instruction.

j. Fan Drives

• Check the pulley alignment by using a straight bar on pulley side plan.
• Groove of pulley must be cleaned.
• Apply belts, loosening the tensioning system to avoid an excessive extension of the
belts and eventual damage. Belt tensioning should be checked with belt tension
gauge.

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• If fan/ motor has been once replaced, check the direction of drive rotation. The
direction is indicated on the casing by an arrow on ventilation fan.

k. Damper

• Damper shall operate according to its design requirement.

• Replace damper blade gasket if worn out (if applicable).

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