22 22 22

49 49 49
5, 5, 5,
K K K
ev ev ev
in in in
,4 ,4 ,4
/3 /3 /3
0/ 0/ 0/
20 20 20
20 20 20
1: 1: 1:
28 28 28
:3 :3 :3
2 2 2
PM PM PM

22 22 22
49 49 49
5, 5, 5,
K K K
ev ev ev
in in in
,4 ,4 ,4
/3 /3 /3
0/ 0/ 0/
20 20 20
20 20 20
1: 1: 1:
28 28 28
:3 :3 :3
2 2 2
PM PM PM

CMYK CMYK
 CMYK
PM

PM
2

2
:3

:3
28

28
Preface

1:

1:
20

20
The publishing of this booklet is due to the initiative of Delhi Chapter of ISHRAE, the founder

20

20
0/

0/
chapter of Indian Society of Heating, Refrigerating and Air Conditioning Engineers.
/3

/3
,4

,4
An air handling unit is the heart of the air distribution system in an air conditioning plant.
in

in
Proper selection of the AHU will ensure satisfactory performance of the air conditioning system
ev

ev
and maintenance of the specified indoor air conditions of temperature, humidity, air cleanliness
K

K
5,

5,
and air movement.
49

49
Written in a simple, easy-to-understand style with many diagrams and photos, it will hopefully
22

22
make it easier for the design engineer and installation supervisor to properly select and instal the air
handling unit.
There is nothing original in the contents of this booklet. All the material has been collected
from various sources such as sales catalogs and technical bulletins issued by some manufacturers of
PM

PM
air handling units and trade magazines from USA and UK. My thanks to Rakesh Aggarwal, group
2

2
engineering head, of Caryaire Equipments India Pvt. Ltd., who has been of great help in collecting
:3

:3
28

28
such material.
1:

1:
No attempt has been made to cover the entire theory and practise of various subjects that are
20

20
involved in the design and selection of the major components of the AHU such as the heat transfer
20

20
coils and fans. Several excellent books are available with complete chapters devoted to Psychrometry
0/

0/
/3

/3
and Fan Design and the booklet provides a list of such publications which the reader, interested in
,4

,4
a deeper study of AHUs, can refer to.
in

in
ev

ev
Readers are requested to send in their comments so that future updates can be improved.
K

K
5,

5,
49

49
22

22

Hiru M. Jhangiani
Author, All About AHUs
Mumbai
January 2010
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20

While all possible care has been taken in compiling this booklet, ISHRAE cannot accept responsibility
20

20

for errors and indemnify themselves against any claim that may arise out of the use of any of the
0/

0/

recommendations made herein.

/3

/3
,4

,4

No portion of this booklet may be reproduced or copied, in part or in full, or circulated in any
in

in

manner without permission from ISHRAE.

ev

ev
K

K
5,

5,
49

49

CMYK
22

22

page 1
CMYK

PM

PM
2

2
:3

:3
Contents

28

28
1:

1:
20

20
Selecting the Right Air Quanity........................................................................................................ 3

20

20
Constant Volume or Variable Air Volume System........................................................................... 3

0/

0/
/3 Selecting the Proper Fan Static Pressure........................................................................................... 3

/3
,4

,4
Choosing the Proper Cooling Coil................................................................................................... 3
in

in
Coating of Coils................................................................................................................................. 4
ev

ev
K

K
Horizontal or Vertical AHU.............................................................................................................. 4
5,

5,
Blow-Through or Draw-Through Coil............................................................................................... 5
49

49
Fan Types........................................................................................................................................... 5
22

22
Plug Fans............................................................................................................................................ 5
Face and Bypass Dampers.................................................................................................................. 6
The Electric Motor and its Drive....................................................................................................... 6
Flat Belts............................................................................................................................................ 7
PM

PM
Variable Frequency Drives................................................................................................................. 7
Selecting Air Filters............................................................................................................................ 8
2

2
:3

:3
Use of Heat Recovery Wheels........................................................................................................... 9
28

28
1:

1:
Use of Heat Pipes............................................................................................................................ 10
20

20
Effective Mixing of Fresh and Return Air....................................................................................... 10
20

20
Construction of the Casing............................................................................................................. 11
0/

0/
EN Standard for Mechanical Performance & Classification.......................................................... 12
/3

/3
,4

,4
EN Standard for Rating and Performance of AHUs...................................................................... 12
in

in
Condensation on AHU Panels........................................................................................................ 12
ev

ev
K

K
How Cooling Capacity is Controlled...............................................................................................17
5,

5,

Coil Piping........................................................................................................................................17
49

49

Space Planning ............................................................................................................................... 18

22

22

Unit Positioning............................................................................................................................... 18
Condensation Removal................................................................................................................... 18
Intermediate Drain Pans.................................................................................................................. 20
Flexible Connections....................................................................................................................... 20
PM

Acoustic Treatment of the AHU Room.......................................................................................... 20

PM
Testing and Balancing for Good Performance................................................................................ 20
2

2
:3

:3

Give the AHU the Respect it Deserves........................................................................................... 21

28

28
1:

1:

Installation & Maintenance Manual............................................................................................... 21

20

20

Start-up and Performance Problems................................................................................................ 21

20

20

Calculating Cooling or Heating Coil Performance........................................................................ 22

0/

0/
/3

/3

Checking Actual Cooling Capacity................................................................................................. 23

,4

,4

Analysing Problems with Air Distribution Systems ....................................................................... 24

in

in
ev

ev

Fan Laws, Airflow Formulas used in Air Filtration, Useful Conversions...................................... 26

K

Fan Connections............................................................................................................................. 27
5,

5,
49

49
CMYK

22

22

page 2
 CMYK
PM

PM
2

2
:3

:3
28

28
All About AHUs

1:

1:
20

20
20

20
0/

0/
Introduction factor for air at sea level and DT is the temperature difference
/3

/3
“All About AHUs” provides basic information to the HVAC between room air and supply air.
,4

,4
engineer in selecting, specifying, installing, maintaining and Constant Volume or Variable Air Volume System
in

in
ev

ev
balancing Air Handling Units. The above equation expresses the cooling or heating load
K

K
An Air Handling Unit is designed to provide the function of of a conditioned space as a function of the supply air and the
5,

5,
moving air with a choice of facilities, as required, to achieve air temperature difference DT. From this it can be concluded that
49

49
mixing, air volume control, filtration, cooling, dehumidifying, air handling systems can be categorised into two major groups.
22

heating, humidifying, space pressurisation, energy recovery and
noise as well as vibration control.
The basic components of an Air Handling Unit are a supply
fan, a fan motor, a water cooling coil or a direct expansion
refrigerant coil, filters, a mixing box, dampers, control systems
and a casing. A return fan, heating coils, precooling coils
PM
22
One group will keep the supply air volume constant and rely
on varying the temperature difference to meet the varying
load requirements in the conditioned spaces. The second
group will keep the temperature difference constant and vary
the supply air volume to satisfy the load variation. These two
major groups of air handling systems are commonly referred

PM
and a humidifier may also be included, depending on the to as Constant Volume (CV) and Variable Air Volume (VAV)
2

2
application. systems, respectively.
:3

:3
Next to the packaged chiller or condensing unit the AHU Selecting the Proper Fan Static Presssure
28

28
is the most important part of an air conditioning system. At Manufacturers of AHU’s generally furnish data of their
1:

1:
times even more important, since through the air distribution standard units showing, for each model, supply fan size, coil size,
20

20
ductwork the unit is directly connected to the conditioned space volume flow rate, air velocity at fan outlet, fan static pressure,
20

20
and the user who hears, breathes, works and lives with the air revolutions per minute of fan impeller and brake horsepower
0/

0/
/3

/3
around him or her. The quality of air delivered by the AHU input to fan shaft.
,4

,4
affects occupants of the building in more ways than one. The fan total pressure can be obtained by adding fan velocity
in

in
Many engineers tend to oversimplify the selection of the pressure to the fan static pressure. Velocity pressure, in inches
ev

ev
air handling unit and its installation. Many think of the AHU WG, can be calculated by the equation :
K

Velocity pressure = (outlet velocity)

2
as just a “dubba” or box, which it was, when it was crudely
5,

5,

fabricated from steel sheets around a blower and coil, by any 4005
49

49

steel fabrication shop in India. With the advent of the double where outlet velocity is expressed in fpm.
22

22

skin AHU using aluminium profiles, pre-insulated panels and
plasticised steel skin, the AHU has assumed its rightful pride of
place in an HVAC system and considerable thought and skill
now goes into its design and construction.
This booklet explains the important items that the consultant
PM
An evaluation must be made by the system designer of the
external total pressure drop in the duct distribution system
including silencers, duct heaters and air outlets as well as the
internal pressure loss of the air handling unit including dampers,
filters and cooling/heating coils to ensure that the selected

or design engineer should keep in mind when selecting or fan total meets the system total pressure. See Figure 1 showing PM
specifying an Air Handling Unit. The construction engineer will pressure drop of various internal components of the AHU.
2

Choosing the Proper Cooling Coil

:3

:3

also find some useful hints for a better installation.

28

28

Selecting the Right Air Quantity Having calculated the dehumidified or coil cfm, the velocity
1:

1:

The basic relationship between the space heat load and the across the face area of the cooling coil is selected depending on
20

20

conditioned air required to satisfy this load can be expressed the consultant’s specifications or the design engineers choice.
20

20

as : The most commonly used coil face velocity is 2.57 m/s (500 fpm)
0/

0/

Q = 1.1 × CFM × DT but higher velocities between 550 and 600 fpm are selected by
/3

/3

Where Q, in Btuh, is the sensible load of a conditioned space some designers for a more economical coil selection. At these
,4

,4

at a given time that must be met by supplying a certain volume higher velocities installation of mist eliminators after the cooling
in

in

coil is recommended in order to prevent water carry over to the

ev

ev

of conditioned air at a temperature that is below, for cooling,

duct distribution system. See Figure 2. Velocities above 600 fpm
K

or above, for heating, the space temperature. 1.1 is a conversion

5,

5,
49

49

CMYK

All About AHUs 3

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
or catalog selection procedure.

20

20
Cooling coils can be either DX (Direct

20

20
expansion of refrigerant) or CHW (Chilled

0/

0/
water) and water coils can be either standard
/3

/3
with brazed headers and return bends or
,4

,4
internally cleanable. See Figures 3 and 4. Heating
in

in
ev

ev
coils can be either steam (usually low pressure
K

K
under 5 psig) or hot water. At times both a
5,

5,
cooling and heating coil are installed in series
49

49
for humidity control or for separate cooling and
22

22
heating requirements.
Coating of Coils
Cooling coils are available with a
“Hydrophilic” coating on the aluminum fin
surface to reduce the surface tension of the
condensate water droplets and help in producing
PM

PM
a more evenly dispersed wetted surface. Tests
Pressure Drop

2
have shown as much as 30% reduction in
:3

:3
air pressure drop across a hydrophilic coil
28

28
as opposed to an untreated coil. Having the
1:

1:
condensate as a uniform thin film on the fin
20

20
surface, instead of water droplets, also helps in
20

20
optimizing heat transfer.
0/

0/
Another coating, now available on coils
/3

/3
,4

,4
is “Heresite”, which helps to protect the
in

in
coil against corrosion in salty atmospheres,
ev

ev
commonly prevailing along our long coastline
K

or against fumes in or around chemical and

5,

5,

fertilizer plants.
49

49

Horizontal or Vertical AHU

22

22

In a horizontal unit, the supply fan, coils and

filters are installed at the same level, as shown in
Figure 5. Horizontal units need more floor space
Pressure drop summary
for installation and most such units are installed
inside a fan room or AHU room. At times, small
PM

PM
horizontal units are suspended from the ceiling
inside the ceiling plenum. In these cases fan
2

Figure 1 : Air pressure drop of the various AHU components noise and vibration must be carefully controlled
:3

:3
28

28

are not recommended. if the unit is adjacent to the conditioned space.

1:

1:

A higher face velocity results in a smaller coil, a higher heat In a vertical unit, the supply fan is not installed at the same
20

20

transfer coefficient, a greater pressure drop across the coil and level as the coils and filters but at a higher level as shown in
20

20

filter and a smaller fan room. While a lower coil face velocity Figure 6. Vertical units require less floor space. They are usually
0/

0/

has a larger coil, a lower heat transfer coefficient and a smaller smaller, so that the height of the coil section plus the fan section
/3

/3

pressure drop. A good system designer will bear all this in mind and the height of the ductwork that crosses over the AHU uner
,4

,4

in selecting the AHU. the ceiling is less than the headroom (the height from the floor
in

in

to the ceiling or the beam of the AHU room).

ev

ev

The number of rows deep of the cooling and heating coils is

K

best determined from the coil manufacturers computer program * American Society of Heating, Refrigerating and Air Conditioning Engineers
5,

5,
49

49
CMYK

4 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

K
5,

5,
49

49
22

22
Figure 2 : Mist eliminator made of PVC by Munters India Ltd. Figure 4 : Internally cleanable water coil with cleaning plugs

Blow–Through or Draw–Through Coil Fan Types

PM

PM
The terms “blow–through” and “draw–through” are self Fans or blowers provide the energy to move the air through
2

2
explanatory regarding the location of the fan in relation to ducts and the other accessories that form the air side of an
:3

:3
the coil. A “draw–through” arrangement, as shown in Figure HVAC system such as grilles, diffusers, air filters, humidifiers,
28

28
5 provides the simplest approach to even air flow across the dampers etc.
1:

1:
face of the coil. ASHRAE* considers the air flow to be uniform Two types of centrifugal fans are commonly used in air
20

20
when velocity measurements across the coil vary no more handling units, the forward curved type and the airfoil blade
20

20
than 20 percent. Draw–through units are the most widely or backward inclined type, see Figure 8. The latter type is more
0/

0/
/3

/3
used AHUs. efficient but the forward curved type is generally smaller for a
,4

,4
Putting the coil in the “blow–through” position (i.e. given duty and lower in first cost and hence more commonly
in

in
downstream of the fan) usually requires the installation of baffles used. The fan RPM is selected in order to meet the required
ev

ev
or diffuser plates between the fan discharge and the coil. This system total pressure loss, that is the external pressure loss
K

introduces additional presssure drops and requires a higher plus the pressure loss within the AHU. An exploded view of a
5,

5,

fan hp. If a baffle plate is not installed the velocity across the backward-curved centrifugal fan is shown in Figure 9.
49

49

face of the coil will not be uniform and can cause problems Plug Fans
22

22

with water carryover at the centre of the coil and affect overall Also referred to as unhoused centrifugal fans or cabinet fans,
performance. these are centrifugal fans with no outer casing or scroll. The
impeller is generally directly mounted on the driving motor shaft
and the entire assembly mounted in a cabinet or a plenum, which
is pressurised by the operation of the fan. This permits supply
PM

air ducts coming from any direction to be directly connected to PM

2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

Figure 3 : DX(Direct Expansion) coil with liquid distributor at inlet Figure 5 : A horizontal draw-through AHU
5,

5,
49

49

CMYK

All About AHUs 5

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

K
5,

5,
49

49
22

22
Figure 8 : Schematic view of the construction of (a) backward-curved fan
and (b) forward-curved fan
bulb temperature, the space relative humidity will increase.
By using a face and bypass damper, Figure 11, and operating
the cooling coil at full capacity, the space relative humidity can be
controlled. A percentage of the supply airflow is bypassed around
PM

PM
the cooling coil while the balance of the air passing through
Figure 6 : A vertical draw-through AHU the cooling coil is cooled to a significantly lower dry bulb/wet
2

2
:3

:3
the casing, thus saving space and cost. bulb condition, lowering the relative humidity. The results of
28

28
Such fans are often used in large capacity roof top packaged mixing the air off the cooling coil with the bypass air are supply
1:

1:
units and in “clean” rooms. See Figure 10. air conditions that will allow for a high latent cooling load,
20

20
Face and Bypass Dampers therefore, maintaining control of the space relative humidity.
20

20
In regions with high humidity, the face and bypass damper is Consider the specific job conditions before applying face and
0/

0/
used as a method of humidity control. External face and bypass bypass for humidity control. This application works best with a
/3

/3
,4

,4
dampers are placed immediately upstream of the primary cooling small percentage of outside air.
in

in
coil. The space relative humidity problems occur at part-load The Electric Motor and its Drive
ev

ev
conditions, assuming that the cooling coil is properly sized for The blower motor is mounted inside the unit leading to
K

full-load conditions in the space. quieter operation. An inspection door in the AHU provides ready
5,

5,

The loss of space humidity control occurs as a result of the access to the motor and the V - belt drive for maintenance.
49

49

changing sensible heat ratio (SHR) during part loads. In humid In this space-age most electric motors are extremely reliable
22

22

climates, the sensible loads decrease more than the latent loads
at part-load conditions. The result is a sensible heat ratio that
decreases, or on the psychrometric chart, the SHR line becomes
steeper. If the cooling coil is being controlled by a constant dry
PM
in operation and seldom fail. In the rare event of a motor failure,
a replacement motor, if available as a spare, can be installed in
an hour or two at the most. If this delay cannot be tolerated
for any reason, the system designer may insist on a standby

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev

Figure 7 : A special AHU with a heat recovery wheel, supply fan and
K

exhaust fan. See page 7 for explanation of a heat recovery wheel. Figure 9 : Exploded view of a backward-curved centrifugal fan
5,

5,
49

49
CMYK

6 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

K
5,

5,
49

49
22

22
Figure 12 : Typical layout of blower with normal running and standby
Figure 10 : A plug fan installed in a plenum motors at opposite ends

motor installed within the unit and ready to be switched on at speed. The adjustable pitch pulley, see Figure 15, can come in
PM

PM
immediate notice. Such standby motors can be incorporated handy, under these circumstances, while the fixed pitch pulley
in AHUs at the manufactures’ design stage, see Figure 12. An would have to be replaced with a smaller diameter, causing delays
2

2
:3

:3
“airflow” switch can also be installed at the fan outlet to indicate in system balancing.
28

28
“no airflow” to the operator. Estimated belt drive losses are shown in Figure 16 and will
1:

1:
Blowers are driven by an electric motor either direct, help in proper motor selection.
20

20
(generally smaller motors 1 hp and below) see Figure 13, or by Flat Belts
20

20
a V - belt drive using a standard 50 Hz 1440 rpm motor. See Flat belts are also available as an option to V-belt drives.
0/

0/
Figure 14. In case of a V-belt drive it is advisable to specify a Today’s high-efficiency flat belts with a high tensile strength
/3

/3
,4

,4
minimum of two belts, so that in case one belt breaks or is loose, result in more compact and cheaper drives that need less
in

in
the second belt can ensure fan operation until the maintenance maintenance for retensioning or shortening of the belt.
ev

ev
crew rectifies the defect. Variable Frequency Drives
K

The motor sheave or pulley can be either of a fixed pitch VFD or variable frequency drive is a system for controlling
5,

5,

or a variable pitch in case the fan speed needs to be changed to the speed of an AC motor by controlling the frequency of electric
49

49

balance the blower with air distribution system characteristics. power supplied to the motor. Significant energy can be saved
22

22

Most system designers build in a large margin of safety in the
fan static pressure calculations and upon operation, the system
static pressure turns out to be lower than the design, leading to
a larger air supply than required and necessitating a reduced fan
PM
by using a VFD to achieve variable-air volume control. Changes
in static pressure drop across HEPA air filters commonly
used in air conditioning systems for pharma plants, hospital
operating theatres and “clean” rooms, can also be offset by

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

Figure 11 : Face and bypass dampers Figure 13 : A direct driven blower with motor
5,

5,
49

49

CMYK

All About AHUs 7

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
simply regulating the S.No.
Dust Spot Efficiency Arrestance MERV* Rating
EN779+ EUROVENT 4/9 In India, known as:

20

20
fan speed with the help ASHRAE 52.1 ASHRAE 52.1 ASHRAE 52.2

20

20
of a VFD. 1. Less than 20% 60-80% MERV 1-4 G2 EU2 Coarse Filters

0/

0/
Selecting Air Filters 2. Less than 20% 80-90% MERV 5 G3 EU3 Pre Filter, 90% @ 20 microns
/3

/3
The air handling unit 3. 20-30% 90-94% MERV 6 G4 EU4 Pre Filter, 90% @ 10 microns
,4

,4
is expected not only to 4. 30-35% 90-94% MERV7 G4 EU4 Pre Filter, 90% @ 10 microns
in

in
ev

ev
cool and dehumidfy the 5. 40-55% 95-98% MERV 8-9 F5 EU5 Fine Filter, 99% @ 5 microns
K

K
air but also to remove 6. 60-80% 96-99% MERV 10-12 F6 EU6 Fine Filter, 99% @5 microns.
5,

5,
impurities suspended 7. 80-90% 98-99% MERV 13 F7 EU7 Super Fine Filter, 99% @3 microns.
49

49
in the air with the help 8. 90-95% 99% MERV 14 F8 EU8 Super Fine Filter, 99.5% @3 microns.
22

22
of efficient air filters. 9. 95% + 99%+ MERV 15 F9 EU9
Extra Fine Filter >75% @0.3 microns.
90-95% @ 1 micron.
System designers and
AHU specifiers must not 10. 95% DOP NA MERV 16 H10 EU10
Not made as a standard
overlook this important 11. 98% DOP NA MERV 16 H11 EU11

aspect of an AHU. 99.97%@ 0.3µ H12 EU12 HEPA FILTER

12. NA NA
99.99%@0.3µ H13 EU13 HEPA FILTER
Regardless of its
PM

PM
13. 99.999%@ 0.3µ NA NA H14 EU14 HEPA FILTER
source, an airborne con-
14. 99.9995%@0.12µ NA NA U15 EU 15 ULPA FILTER. Not made as a standard
2

2
taminant can be either
:3

:3
* Minimum Efficiency Reporting Value + One of two different European Standards
an aerosol or a gas. An
28

28
Table 1: Classification of filters.
aerosol is a suspension
1:

1:
of solid or liquid particles in the air. The size of an aerosol is usu- tend to stay suspended in the air or settle very slowly. Airborne
20

20
ally measured in microns. A micron is one millionth of a meter dust particles less than 0.1 micron behave like gases and have
20

20
or 1/25,400 inch. Under the International System Units (SI) no rate of fall. Those in the range of 0.1 to 1.0 microns have
0/

0/
“micron” is being replaced by “micrometer”. However “micron”
/3

/3
negligible settling velocities while those in the range of 1.0 to 10
,4

,4
is currently the more popular term with the filter industry. The microns have constant and appreciable settling rates but are kept
in

in
abbreviation for this unit of measurement is m. in suspension by air currents. Particles larger than 10 microns
ev

ev
Figure 17 helps visualise the size of a micron by relating this will normally settle out of the atmosphere.
K

dimension to the size of human air and other objects. Currently all major filter manufacturers in the USA rate their
5,

5,

There are different aerosols, depending on their source of performance in terms of ASHRAE 52.1 and 52.2. Performance
49

49

generation - dusts, fumes, fogs, mists and smokes. Dusts are solid values remain unchanged for the same filter tested by either
22

22

aerosols generated from the reduction of larger solid materials. method. This method requires both an atmospheric dust spot
For example a drill creates dust while drilling holes in a rock. discoloration test which defines the "Efficiency" and a synthetic
Larger dust particles settle rapidly. Smaller dust particles dust weight test which defines "Arrestance". Filters with average
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev

Figure 15 : An adjustable pitch motor pulley for small variations in blower

K

Figure 14 : A belt driven blower speed

5,

5,
49

49
CMYK

8 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

K
5,

5,
49

49
22

22
Figure 17 : Size in microns of certain small particles
tube manometer will also serve this purpose. See Figure 19. A
record should be maintained of the “clean” filter pressure drop
Figure 16 : Estimated belt drive losses and the maximum tolerable “dirty” filter drop and the cleaning
PM

PM
efficiencies below 20% or above 98% are not considered suitable or replacement cycle determined accordingly.
2

2
for the atmospheric dust spot test. Filters below 20% efficiency Use of Heat Recovery Wheels
:3

:3
are tested by the “Arrestance" procedure and above 98% by the Wherever a high percentage of outside air is introduced into
28

28
"DOP" procedure. See typical filter selection guide Figure 18 by an air conditioned area for improved ventilation and reduced
1:

1:
a US manufacturer. pollution, a Heat Recovery Wheel is used as an integral part of the
20

20
Table 1 shows a classification of filters comparing both AHU for heat recovery and energy conservation. See Figure 20.
20

20
ASHRAE and European Standard Ratings (EN 779 and The Heat Recovery Wheel can recover both sensible
0/

0/
/3

/3
Eurovent 4/9). (temperature) and latent (moisture) energy. As the wheel or rotor
,4

,4
Selecting the proper efficiency, the right quality, and slowly rotates (approximately 20 rpm) between the outdoor and
in

in
maintaining the filters in a clean condition, all have a bearing on return air streams, the warm outdoor air is cooled by the return
ev

ev
keeping the air conditioned space clean, as dust free as possible air before it is exhausted and simultaneously the high moisture
K

and preventing ugly, dark smudge marks

5,

5,

around supply air ceiling diffusers. To prevent

49

49

smudging and discolouration of building

22

22

interiors where smoking is allowed, medium

efficiency filters of dust spot efficiency greater
than 65 percent are preferable. A prefilter can
extend the service life of the bag filter.
Velocity across the filter face area is generally
PM

the same as across the cooling coil though PM

lower velocities, as recommended by the filter
2

2
:3

:3

manufacturer, may by used, space permitting.

28

28

The only reliable method of determining

1:

1:

when filters need cleaning or replacement,

20

20

if the filters are of the disposable kind, is to

20

20

instal a gauge across the two sides of the filter

0/

0/

on the AHU (air entering side and leaving

/3

/3

side) which reads the pressure difference or

,4

,4

pressure drop across the filter. Such a gauge

in

in

is called a “Magnehelic” gauge and is typically

ev

ev
K

manufactured by Dwyer, USA. An inclined Figure 18 : Filter selection guide by particle size
5,

5,
49

49

CMYK

All About AHUs 9

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

K
5,

5,
49

49
22

22
Vp – Purge/Seal Airflow Vs – Supply Ve – Exhaust

Figure 19 : Inclined gauge manometer installed across an air filter and a
differential pressure Magnehelic gauge
content in the outdoor air is reduced by the lower moisture
content in the exhaust air.
Typical installations involve hospitals, hotels, theatres,
PM
Figure 21 : Typical fan locations for a Heat Recovery Wheel
condenser to re-heat air coming out of the cooling coil.
Using a heat pipe, thermal energy can be recovered from
warmer air and added to cooler air. In temperate climates, this

PM
auditoriums, laboratories and other high occupancy areas or permits energy saving to be realized through preheating of the
2

2
industrial process areas which produce contaminants. outside air. Conversely in hot climates the savings are associated
:3

:3
The selection of the Heat Wheel and its performance with pre-cooling of the outside air. See Figure 20.
28

28
calculation can be obtained from the manufacturer of the wheel. Heat pipes can increase an air handler moisture removal
1:

1:
Typical fan locations are shown in Figure 21. capacity by 50% to 100%. Heat pipes not reduce the chiller load
20

20
Use of Heat Pipes by free pre-cooling but also provide free reheating to lower the
20

20
A Heat Pipe is a finned type of heat exchanger with sealed relative humidity of supply air. As most of today’s primary indoor
0/

0/
/3

/3
copper tubes. It has two parts—evaporator to pre-cool and air quality concerns are humidity related, the health benefits of
,4

,4
heat pipes are noticeable.
in

in
Effective Mixing of Fresh and Return Air
ev

ev
AHUs for air conditioning applications generally include a
K

mixing box where the fresh and return air are supposed to mix
5,

5,

evenly before starting their compact or short journey through the

49

49

filters, cooling and/or heating coils, humidifier and the blower.

22

22

When fresh air quantities become large and temperature/relative

humidity of the fresh air and return air are greatly different,
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

Figure 20: Heat Recovery Wheel (top) and Heat Pipe schematic arrangement (below) Figure 22 : Static mixers installed in mixing box
5,

5,
49

49
CMYK

10 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
in the AHU. Figure 22 shows Blender Products (a manufacturer

20

20
in USA) static mixers installed in a mixing box.

20

20
Construction of the Casing

0/

0/
At one time all factory fabricated air handling units were of
/3

/3
“single skin” construction with galvanised steel sheets, suitably
,4

,4
reinforced with stiffeners, forming all the side and top panels with
in

in
ev

ev
a drain pan insulated from the inside, see Figure 23. Stiffeners
K

K
or heavy gauge steel sheets were used to prevent the units from
5,

5,
vibrating and making noise during operation. Panels were
49

49
insulated from the inside, generally with fibreglass, to prevent
22

Figure 23 : A single skin AHU
stratification tends to occur in the standard mixing box leading
to uneven filtration and cooling or heating of the supply air.
In the winter months when the outside air temperature falls
PM
22
condensation and provide acoustic effect to dampen noise. In
the course of time this insulation tended to peel off the panels,
accumulate dust, get damaged and fibres from the insulation
material get mixed with air stream. This was an unsatisfactory state
and the need was felt for improved design and construction.
As industry progressed, aluminium extrusions became

PM
below freezing temperature, stratification can cause frozen water common and European manufacturers first introduced the
2

2
coils and tripping of the low temperature limit controller (freezestat). double skin construction, using aluminium extrusions, see Figure
:3

:3
During summer months, the effects of stratification are usually poor 24, in a frame in which double skin, metal sandwich panels could
28

28
mixed air temperature control and increased energy usage. be bolted. The polyurethane foam insulation injected between
1:

1:
The importance of stratification has also increased as a result two metal panels gave the panels additional rigidity for the same
20

20
of the new concerns over indoor air quality (IAQ) and revised thickness as fibreglass, leading to the use of 0.6mm thickness gi
20

20
standards for larger quantities of fresh air in buildings where sheets as an industry standard. Prepainted galvanised sheets or
0/

0/
plastic coated sheets followed later giving the AHUs an aesthetic
/3

/3
human beings work or gather for entertainment and lectures
,4

,4
such as hospitals, hotels, offices, cinema halls, auditoriums, look, not imaginable with the early single skin gi panels.
in

in
conference/exhibition centres etc. Such double skin, aluminium frame, puf insulation and tough
ev

ev
To overcome this problem static air mixers have been designed plastic coated galvanised steel sheet construction gives AHUs
K

to fit inside the mixing box of the AHU and can be provided by many advantages such as quieter operation, (since the double
5,

5,

some AHU manufacturers, if requested. When installed correctly, skin panels muffle the sound of the fan and the motor located
49

49

the velocity profile downstream of the mixer and the pressure drop inside), clean inside finish of the unit (ideal for hospitals, “clean”
22

22

can be predicted since the product is factory made and installed rooms, hotels, offices and wherever human beings occupy an air
conditioned space) and, of course, better aesthetics.
AHUs should preferably be located indoors in air handling
unit rooms but can be located outdoors in mild weather with
a separate sloping roof over the units to prevent rain water
PM

damage. See Figure 25. PM

2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev

Figure 24 : Aluminium extruded profiles of different shapes forming the

K

frame of a typical double skin AHU Figure 25 : Exposed AHU with protection cover
5,

5,
49

49

CMYK

All About AHUs 11

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
Mechanical Performance and Classification

20

20
EN 1886:2007 is a European Standard, prepared by the

20

20
European Committee for Standardization, or CEN, for short,

0/

0/
which is part of a series of standards for air handling units used
/3

/3
for ventilation and air conditioning of buildings for human
,4

,4
occupancy. It considers the mechanical performance of an AHU
in

in
ev

ev
as a whole and will be supported by a standard for sections
K

K
and components. The standard specifies test methods, test
5,

5,
requirements and classifications for AHUs which are supplying
49

49
and /or extracting air, via ductwork, for a part or the whole
22

22
building, except :
• fan coil units
• units for residential buildings
• units mainly for a manufacturing process
There are six test criteria for this Standard : mechanical Figure 27 : Variable inlet vane
strength, air leakage, filter bypass leakage, thermal transmittance, such cases, generally no condensation occurs on the AHU panels
PM

PM
thermal bridging and acoustic insulation, Except for the last or profiles. Most AHU’s for comfort application are installed
2

2
test, all other tests can be carried out by an international test in this manner.
:3

:3
laboratory in India. However when the return air is ducted to the AHU, as
28

28
Rating and Performance of AHUs is common in industrial applications such as pharmaceutical
1:

1:
The European Standard EN 13053:2006 covers the rating plants or when the AHU is drawing in 100% fresh air such as
20

20
and performance for air handling units, components and for “fresh-air-treatment” in hotels or hospitals, the space around
20

20
sections and has been prepared by the European Committee the AHU is exposed to ambient or outdoor conditions. In such
0/

0/
/3

/3
for Standardization or CEN, for short. cases, condensation on the AHU panels, in the peripheral area
,4

,4
Today, only Eurovent in Europe has the facilities and near the aluminium profile framework, can occur, particularly in
in

in
authority to test and certify the performance of AHUs complying coastal areas or high humidity locations such as Mumbai, Goa,
ev

ev
with this Standard. Trivandrum, Chennai, and Kolkata when ambient air is at 20°
K

Condensation on AHU Panels to 30°C with relative humidty of 65 to 85% and above. The
5,

5,

When an AHU is installed in a room which acts as a return problem is aggravated when the temperature inside the AHU
49

49

air plenum, the panels and frame (of aluminium profiles) of is 6° to 13°C which is very low and abnormal but can occur if
22

22

the AHU are exposed to return air which is almost at the same
temperature and relative humidity as the conditioned space. In
Thermal Barrier
PM
the blower is switched off but chilled water keeps circulating
inside the cooling coil.
This problem is similar to the condensation occurring on the
outside surface of a glass of chilled water in the humid summer
months in Mumbai when the glass surface temperature is lower

than the dew point of the ambient air. PM

To reduce the severity of this problem, AHUs can be
2

2
:3

:3

fabricated with special aluminium profiles that have a built-in

28

28

thermal barrier seperating the inside and outside of the profile.

1:

1:

See Figure 26. Also, the panels are manufactured with a thermal
20

20

barrier between the inner and outer skin.

20

20

It is commonly perceived that AHUs with thermal break

0/

0/

construction will not sweat. It should be realised however

/3

/3

that “thermal breaks” do not eliminate condensation on the

,4

,4

profiles and panels but merely increase the difference between

in

in

Thermal Barrier the surface temperature inside and outside the AHU casing
ev

ev

thereby increasing the range of ambient conditions at which

K

Figure 26 : Special aluminium profiles with thermal barrier

5,

5,
49

49
CMYK

12 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
will require some modification to

20

20
the control scheme. Since refrigerant

20

20
flow cannot be controlled as easily

0/

0/
as chilled water flow can, by a three-
/3

/3
way valve, capacity can be controlled
,4

,4
by splitting the coil in two or three
in

in
ev

ev
sections with each section having an
K

K
independent expansion and solenoid
5,

5,
valve. Alternately the coil can be
49

49
split across the face area, so that, for
22

22
example a six row coil can be circuited
two rows in one circuit and four rows
in a second circuit with each circuit
having an independent expansion
and solenoid valve. The solenoid
valves can be controlled by a two
PM

PM
stage room thermostat or a return air
2

2
thermostat.
:3

:3
Coil Piping
28

28
There are some items that must
1:

1:
always be included on coil piping, see
20

20
Figure 28. One of the most important
20

20
Figure 28: Typical chilled water coil piping with accessories
is a means of accurately determining
0/

0/
/3

/3
condensation will occur. Please refer any such special application pressure and temperature differences between the coil inlet
,4

,4
or problems to the AHU manufacturer for his guidance. and outlet. On coils over 2m2 (20 sq. ft.) install pressure gauges
in

in
How Cooling Capacity is Controlled and thermometers on both the supply and return piping. On
ev

ev
There are several ways of controlling the capacity of an air smaller coils, provide carefully located pressure/temperature
K

handling unit using a chilled water coil. taps for use with accurate insertion thermometers or pressure
5,

5,
49

49

• The simplest way is to have a bypass damper around the coil, instruments. These instruments provide the most important
22

22

the damper being operated by a damper motor controlled by
a return air or room thermostat. When the damper is fully
open, a limit switch on the damper motor can actuate an
on - off, two way valve on the supply line to the CHW coil
thus stopping all water flow through the coil.
• A refined version of the above method can substitute a face-
PM
means of trouble shooting the coil. The pressure gauges will tell
you if the coil has developed a blockage and the thermometers
with the flow control valves will allow you to calculate the actual
capacity of the coil.
A strainer on the supply line will collect rust flakes, welding
slag and other debris that may be left behind between the

and-by pass damper across the coil with a three- way valve to pump strainer and the coil. It is a lot easier to clean a strainer
PM
help maintain constant flow through the chiller.
2

2
:3

:3

• Some designers eliminate the dampers altogether and

28

28

control water flow through the coil by means of a three way

1:

1:

modulating valve only.

20

20

• A Variable Frequency Drive (VFD) can be used to modulate

20

20

the fan speed and thus control the fan cfm in response to
0/

0/

a return air or space thermostat. This is normally used in

/3

/3

VAV (Variable Air Volume) systems . The Variable Inlet

,4

,4

Vane (VIV), see Figure 27, control on the fan inlet is another
in

in
ev

ev

common method used in VAV systems.

K

• Direct expansion coils when used in an air handling unit Figure 29 : Coil piping with provision for coil pullout
5,

5,
49

49

CMYK

All About AHUs 17

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
avoid damaging stresses on panels and on the frame during the

20

20
joining of the various sections. A water level should be used to

20

20
position the unit, adding shims if necessary to facilitate the easy

0/

0/
opening of the inspection doors
/3

/3
The unit can be installed directly on the floor so long as it
,4

,4
can bear its weight and also allow the drain trap to be installed
in

in
ev

ev
below the unit. If necessary the unit can be raised off the floor
K

K
by inserting concrete blocks or metal profiles such as channels or
5,

5,
I beams. See Figures 30, 31 and 32. Sometimes a concrete house
49

49
cleaning pad is built under the entire unit with adequate height
22

22
to accommodate the trap.
Anti-vibration mounts are not needed between the unit
base and the floor, as the internal moving parts are dynamically
Figure 30 : A unit mounted on concrete blocks
isolated from the structure of the unit. For very critical
than it is a coil and the strainers are a cheap insurance to avoid applications, expert advice must be obtained from noise and
trouble later. vibration consultants.
PM

PM
When installing the piping to the coil, offset the supply and It is recommended that enough space be provided around
2

2
return risers so that they don’t intrude into the coil-pull space. the unit for proper maintenance and replacement of any
:3

:3
When the coil has to be pulled the maintenance crew only have components at a future date.
28

28
to break one joint on the supply and one on the return making Condensation Removal
1:

1:
their job easier. See Figure 29. In most air handling units condensation of water vapour
20

20
Space Planning in the air occurs over the surface of the cooling coil. In coastal
20

20
The AHU should be so located that there is enough room areas with high humidity this condensation is very heavy and
0/

0/
to be able to pull out the coil should it ever have to be removed, proper care must be taken to drain this water quickly. The
/3

/3
,4

,4
for cleaning, to repair a leak or just replacement. The ideal drain pans in AHUs are generally sloped to provide positive
in

in
arrangement requires room more than twice as long as the coil drainage to the pan outlet avoiding the pools of stagnant water
ev

ev
but unfortunately this much room is seldom available from the that are prime breeding grounds for bacteria, moulds and algae.
K

architects. Hence the next best thing to do is to position the Once the water has reached the pan drain outlet, it is upto the
5,

5,

doors to the AHU room so that the doors are opposite the coil planning engineer and the site erection supervisor to dispose
49

49

and when opened the space outside the doors can be utilised as
22

22

the coil-pull space. The only other option involves constructing

part of the AHU room wall so that it can be easily dismantled
to permit coil pull-out.
Unit Positioning
The air handling unit must be installed on a level surface to
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

Figure 31 : A unit mounted on I beams Figure 32 : A unit mounted on a raised platform

5,

5,
49

49
CMYK

18 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
bacterial growth and
Draw-Through discharge

20

20
condensation on the

20

20
wall surfaces. A water

0/

0/
trap, also called a U
/3

/3
trap, must therefore
,4

,4
be installed in the
in

in
ev

ev
condensate drain
K

K
piping. Without a
5,

5,
trap, static pressure
blow-Through discharge
49

49
within the air handler
22

22
can prevent proper
drainage, causing water
overflow, air handler
flooding and possibly
property damage.
Figure 29 shows a good
PM

PM
example of such a
Figure 33 : Condensate U traps and their heights
2

2
trap.
:3

:3
of it through piping. Because condensation drains by gravity, the elevation
28

28
There are several issues that have to be taken into account difference between the bottom of the drain pan and the outlet
1:

1:
while designing the condensate or drain piping. The drain pan of the trap must be sufficient to be certain that no standing water
20

20
outlet is typically on the downstream side of the coil on the remains in the pan due to the pressure differential between the
20

20
suction side of the fan, in the case of “draw–through” units. The inside and the outside of the air handler. This also has a bearing
0/

0/
on the depth of the U - trap which must be at least 1. 5 times the
/3

/3
pressure at this point in the air handler is lower than the ambient
,4

,4
atmospheric pressure and hence outside air would be sucked in pressure in the drain pan to prevent the water seal from being
in

in
through the drain line. This incoming air stream has sufficient broken. See Figure 33 for more details both for a “draw–through”
ev

ev
velocity to launch the water droplets forming at the base of the and a “blow–through” air handler.
K

coil into the air. Air flowing through the coil can then spray this Cleanouts must also be provided to simplify periodical
5,

5,

condensate into the fan intake, which can propel the moisture cleaning of any biological growth in the piping. See Figure
49

49

into other parts of the system. The resultant aerosol mist can be 34. The AHU must be raised sufficiently above floor level to
22

22

carried through the ducts and into the conditioned space causing provide height and space for installing the water trap and every
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

Figure 34 : Provision for trap cleaning Figure 35 : Intermediate drain pans

5,

5,
49

49

CMYK

All About AHUs 19

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
Acoustic Treatment of the AHU Room

20

20
When the single skin AHU was the standard in the

20

20
industry, AHU rooms were often acoustically treated to

0/

0/
reduce AHU noise in the air conditioned spaces. Blower
/3

/3
motors in such AHUs were usually mounted outside the unit
,4

,4
and the motor noise coupled with the belt drive noise made
in

in
ev

ev
acoustic treatment of the room almost a necessity, since the
K

K
room was used as a return air plenum.
5,

5,
With the advent of the double skin AHU with the
49

49
motor and drive mounted inside the unit on a floating
22

22
spring isolated base, a flexible connection on the fan outlet
and double- wall, insulated AHU panels the noise is sealed
inside the unit and hence acoustic treatment of the AHU
Figure 36 : A flexible connector
room can be safely eliminated in most installations saving
AHU room must have a floor drain that can carry away the a considerable sum of money. Critical applications such as
condensate water. auditoriums, lecture halls, sound studios and other similar
PM

PM
Intermediate Drain Pans applications will however require special advice from acoustic
2

2
On cooling coils that are more than 115cms (45 inches) experts about the need for such treatment as well as the
:3

:3
in height water droplets running down the face of the coil installation of duct silencers.
28

28
get large enough to be entrained into the air stream even at Testing and Balancing for Good Performance
1:

1:
2.57m/s (500 fpm). To get the required face area, coils may New systems are never really balanced by themselves. In
20

20
have to be stacked two or three high. To prevent condensation new systems it is possible that only half the amount of air
20

20
from being blown into the air stream as it drips from one coil reaches the end outlets and double the required amount flows
0/

0/
/3

/3
to the next, intermediate drain pans or troughs should be out from the outlets near the fan resulting in hot and cold
,4

,4
provided. This is illustrated in Figure 35.These intermediate areas. Fans may be running too fast or slow, either wasting
in

in
troughs drain down into the main drain pan. ASHRAE energy or performing inadequately. Too much or too little
ev

ev
recommends that these intermediate drain pans extend outside air may be drawn in resulting either in excessive
K

downstream of the coil at least half the height of the coil. In energy costs or unhealthy air quality conditions.
5,

5,

practise if you maintain a face velocity below 2.57 m/s (500 Even if balanced originally, existing systems become
49

49

fpm), an extension of 30 cms (12 inches) will suffice. Keep in imbalanced due to adjustments by occupants, architectural
22

22

mind that the higher the face velocity the farther the drain
pans must extend from the coil face.
Flexible Connections
A flexible connection is required between the fan outlet
and the supply air duct to prevent fan vibrations being
PM
remodelling in the spaces, HVAC system alterations and
different use of spaces. In addition:
• Balancing can provide a 5 to 10% saving in energy
costs.
• Balancing improves HVAC performance in terms of

transmitted to the ductwork with consequent noise in the comfort, health and occupants work output. PM
conditioned space. The length of the flexible connection • Balancing provides correct air flows at fans and outlets
2

2
:3

:3

should be between 7.5 to 10 cms (3 to 4 inches) minimum and correct water flows at pumps and coils.
28

28

for best results. • Problems of design, installation, equipment, operation

1:

1:

Heavy canvas cloth commonly used will serve the purpose and maintenance are uncovered and corrected in the
20

20

but is not the best material for the job since it becomes wet balancing process.
20

20

after use, causing fungus to grow on it, discolor the cloth, • Balancing reduces maintenance and wasting time “putting
0/

0/

generate unpleasant odours and in course of time to tear. out fires”

/3

/3

Imported synthetic material which retains its flexibility for The most common type of HVAC system used is the low-
,4

,4

a long time is used by many companies in their air handling pressure, constant-volume supply system, which is defined
in

in

units as a standard and the flexible connection itself is factory as follows:

ev

ev

• The total system static pressure does not exceed 500 to

K

provided inside each unit, as shown in Figure 36.

5,

5,
49

49
CMYK

20 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
Give the AHU the Respect it Deserves

20

20
Most AHUs are designed with care and manufactured with

20

20
attention to detail. They leave the factory in perfect condition,

0/

0/
properly packed when required. What happens after despatch
/3

/3
is difficult to control especially during the transportation
,4

,4
stage. Unloading and moving into final position or storage,
in

in
ev

ev
if the building is incomplete, is however very much in the
K

K
hands of the HVAC contractor and a good contractor will
5,

5,
take pains in proper unloading and safe storage, adequately
49

49
protected from adverse weather.
22

22
During installation the AHU is often dented by careless
workers or deliberately scratched by others who want to leave
their mark behind. Very often the top of the unit is used
to climb on to and reach piping, insulation or ductwork.
Painters tend to leave paint marks all over the unit. The only
way to protect the unit is to cover it with thick polythene
PM

PM
sheets or tarpaulins. Don’t forget that the AHU can last
2

2
upto 20 years or more, so why disfigure it before it even gets
:3

:3
Figure 37 : Pressure readings with Magnehelic gauges started on its life journey.
28

28
625 Pa (2 to 2.5 inches water gauge). Installation & Maintenance Manual
1:

1:
• Air velocities do not exceed between 10 and 12 m/s (2000 Most companies can supply a manual that furnishes
20

20
and 2400 fpm). valuable information on loading, unloading, temporary
20

20
The systems are constant air volume and variable storage at site and hints on installation as well as maintenance
0/

0/
/3

/3
temperature. To control the temperatures in the spaces, the that will guide you in the proper installation, commissioning
,4

,4
cooling equipment is cycled on and off or modulated in order and maintenance of your AHU. Feel free to write to the
in

in
to vary air flow and space temperatures. concerned company for a copy.
ev

ev
Testing and balancing or TAB as it is commonly referred Start-up and Performance Problems
K

to, is a subject by itself and several books on the subject are The Air Handling Unit is very often blamed for problems
5,

5,

available. One such book is HVAC Testing, Adjusting, and connected with air distribution system design. A common
49

49

Balancing Manual, third edition, by John Gladstone and W. problem with new systems is excessive air noise caused by too
22

22

David Bevirt, published by McGraw-Hill, USA.
It is good practise to provide some test openings at various
points as shown in Figure 37 and 38 and if provided such
openings should be suitably plugged to prevent air leakage
and noise
PM
much air. System designers have a tendency to play safe and
assume pressure drops in the air duct distribution network
in excess of actual. As a result the blower is selected for an
external static pressure far in excess of what is required,
resulting in excess air supply.

To intelligently tackle such problems the supervising PM

engineer must know the Basic Fan Laws which provide the
2

2
:3

:3

needed calculations to adjust pulley sizes, change rpm, project

28

28

new static pressures, and determine required horsepower.

1:

1:

Each of these laws follows the laws of physics, and their

20

20

relationships to one another change in set and predictable

20

20

patterns. Thus :
0/

0/

• Rpm varies at an equal proportion to air volume.

/3

/3

• System pressures vary as the square of the air volume.

,4

,4

• Amperage varies as the cube of the air volume.

in

in

To determine the new performance of a system at a new

ev

ev

CFM, take the following steps :

K

Figure 38 : Measuring system air flow

5,

5,
49

49

CMYK

All About AHUs 21

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
1. Find the ratio of the existing CFM to the new CFM Methods are available to calculate the performance of a coil

20

20
desired: under any conditions with considerable accuracy. If the flow

20

20
rates of air and water remain unchanged, calculations are simple
Old and new CFM ratio = CFM new

0/

0/
enough to be done by an HVAC engineer without expertise in
/3

/3
CFM existing heat transfer. However, most HVAC engineers are not aware of
,4

,4
2. To find the new system rpm, multiply step one by the these methods and face considerable difficulties when the need
in

in
existing rpm:
ev

ev
for such calculations arises.
New rpm = CFM new
K

K
× existing rpm Two formulas follow by which the effects of changing air
CFM existing
5,

5,
and water temperatures can readily be calculated. Their use is
49

49
3. To find new system static pressure, multiply step one, illustrated by three examples.
22

22
squared, by the existing static pressure: Formulas
( CFM new )2 existing static For purely sensible heating or cooling, the following equation
New Static pressure = × pressure
CFM existing should be used:
4. To find new motor amperage, multiply step one, cubed, Q1 (Ta1 - Tw1)
by the existing motor amperage: =
( CFM new )3 Q2 (Ta2 - Tw2) (1)
New motor amps = × existing motor amps
PM

PM
CFM existing where Q = heating or cooling capacity of coil
The problem of excessive air can now be resolved by Ta = temperature of air entering the coil
2

2
:3

:3
measuring the total air quantity and existing fan rpm, referring Tw = temperature of water entering the coil
28

28
to the fan curves or rating charts and with their help determining Subscripts
1:

1:
the new fan rpm required to give the design air quantity. If 1 = conditions at which performance is known
20

20
necessary (if an adjustable pitch pulley is used, reduce the pitch 2 = conditions at which performance is needed
20

20
diameter to reduce blower speed) the motor pulley diameter may This formula is applicable if the flow rates of air and water
0/

0/
have to be changed. Use the following formula to select the new are unchanged and the changes in temperatures from the design
/3

/3
motor pulley diameter: conditions are moderate, say 20F or less.
,4

,4
Fan pulley dia Design motor rpm When a coil does sensible cooling as well as dehumidification,
in

in
=
ev

ev
Motor pulley dia Design fan rpm the total cooling capacity Qt, can be calculated by the following
K

K
equation :
When changing fan speeds, ask :
5,

5,

Qt1 (ha1 - hw1)

• Will the new setting fall within the fan curve of the
49

49

=
system?
22

22

Qt2 (ha2 - hw2) (2)

• Will the increased electrical load exceed the capacity of the
where
existing motor?
ha = enthalpy of air at coil inlet
• Will the new noise produced by the new settings be
hw = enthalpy of saturated air evaluated at inlet
objectionable?
water temperature
If you use these formulae you’ll be able to adjust fan speeds
Subscripts
PM

and calculate conditions before having to change motors and PM

1 = conditions at which performance is known
drives.
2 = conditions at which performance is needed
2

Calculating Cooling or Heating Coil Performance

:3

:3

This formula should be used only if both the original and

28

28

There are many situations in which the performance

new conditions involve dehumidification.
1:

1:

of heating/cooling coils needs to be known at conditions

Example 1
20

20

other than those for which they were purchased. One such
A switchgear room is provided with a recirculating air
20

20

situation would be that the cooling load has increased –

handling unit that maintains the temperature at 100F. The
0/

0/

what room temperature can now be maintained? Another

unit is rated 100,000 Btuh, with chilled water entering at 55
/3

/3

situation would be that the occupants are complaining that

,4

,4

F. New switchgear (all sensible load) is to be installed, adding a

the building is too hot or too cold – is the coil performing
in

in

load of 10,000 Btuh. Calculate the resulting room temperature

to its full capability, and if so, what can be done to improve
ev

ev

using Equation 1:
the situation?
K

K
5,

5,
49

49
CMYK

22 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
100,000 (100 – 55) • Enthalpy of saturated air at 55 F = 23.2 Btu per lb
=

20

20
110,000 (Ta2 – 55) • Enthalpy of saturated air at 52 F = 21.5 Btu per lb

20

20
Applying Equation 2, we can now calculate the cooling
Ta2 = 104.5 F

0/

0/
capacity at the rating conditions from the test conditions as
/3

/3
Thus, the new switchgear will raise the room temperature follows:
,4

,4
from 100 to 104.5 F.
in

in
1,161,000 (36.8 – 21.5)
Example 2 =
ev

ev
The conditions are the same as in Example 1, but the Qt2 (38.7 – 23.2)
K

K
room temperature must not exceed 102 F. Calculate the Qt2 = 1,179,000 Btuh
5,

5,
49

49
required chilled-water temperature to achieve this, again using The rated cooling capacity is 1,215,000 Btuh. Hence, the
22

22
Equation 1: measured performance is inferior to the rated performance.
100,000 (100 – 55) Checking Actual Cooling Capacity
=
110,000 (102 – Tw2) Actual cooling capacity is something one can easily calculate
once you know the total CFM.
Tw2 = 52.5 F
Drill two 3/8 in. holes before and after the evaporator
Thus a chilled-water supply temperature of 52.5 F is required cooling coil. Read the entering and exiting web bulb
PM

PM
to maintain a 102 F room temperature. temperature by wrapping a moist gauze sock around the bulb
Example 3 of a thermometer and then reading the wet bulb measurements
2

2
:3

:3
An air handling unit was purchased with the following in the air stream.
28

28
performance rating by the supplier: Plot the two readings on an enthalpy chart. Read enthalpy
1:

1:
• Entering air temperature = 95 F db/75F wb by following the chart to the upper left; the difference between
20

20
• Entering chilled-water temperature = 55 F the two enthalpy values is the enthalpy change (Dnt).
20

20
• Leaving air temperature = 66 F db/58 F wb Calculate total cooling output by multiplying CFM by the
0/

0/
• Chilled-water flow = 243 gpm enthalpy change (Dnt) and then multiply the answer by 4.5 (a
/3

/3
• Air flow rate = 20,000 scfm
,4

,4
constant).
The unit was installed and flow rates balanced to the above-
in

in
Total cooling output = CFM × 4.5 × (Dnt)
listed values. The following measurements were then taken:
ev

ev
• Entering air temperature = 90 F db/73 F db
K

K
5,

5,

• Entering chilled-water temperature = 52F

49

49

• Leaving air temperature = 63 F db/56 F wb

22

22

Is the coil’s performance better than or inferior to its rated

performance?
Plotting the rated performance on the psychrometric chart
shows that latent cooling is involved, so Equation 2 will be
used.
• Enthalpy of entering air (he) at 95 F db/75 F wb = 38.7 Btu
PM

PM
per lb
• Enthalpy of leaving air (hl) at 66 F db/58 F wb = 25.2 Btu
2

2
:3

:3

per lb
28

28

• Rated total cooling capacity = 4.5 × cfm (he – hl) = 4.5 ×

1:

1:

20,000 (38.7 – 25.2) = 1,215,000 Btuh (the factor of 4.5

20

20

represents density of standard air multiplied by 60 to convert

20

20

cfm to cfh.)
0/

0/

The enthalpies at measured inlet and outlet air conditions

/3

/3
,4

,4

are 36.8 and 23.9 Btu per lb, respectively.

in

in

• Measured total cooling capacity = 4.5 × 20,000 (36.8 – 23.9)

ev

ev

= 1,161,000 Btuh
K

K
5,

5,
49

49

CMYK

All About AHUs 23

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
Analysing Problems With Air Distribution Systems

20

20
20

20
I. Problem: Spaces Too Hot or Cold • Grilles and ceiling diffusers not dampered down correctly, too large

0/

0/
or wrong type
/3

/3
Possible Causes :
• Filters not installed at all or wrong type Coils wrong size or type
,4

,4
• Too much or too little air being delivered to spaces
in

in
• Air density lower than design because it’s warmer or at higher
• Temperature of air delivered to spaces too hot or cold
ev

ev
altitude
• Thermostat incorrectly set, turned off, malfunctioning, poorly
K

K
• Imbalance in air distribution system.
located, miswired, not calibrated
5,

5,
• Too much air in branches and outlets near fan and not enough in
49

49
• Control dampers incorrectly set or malfunctioning duct runs and outlets
22

22
• Control valves incorrectly set or malfunctioning • Poor temperature control zoning of system to accommodate
• lnternal heat generation in room more than designed, causing changing heating/cooling loads during day, or poor mixture of
excessive heat gain spaces on the same zone.
• Fluid flow volume or temperatures at coils incorrect
• Coils dirty or clogged III. PROBLEM: Not Enough Air
• Terminal boxes not operating properly Possible Causes :
PM

PM
• Errors in heating or cooling load calculations
• Supply diffuser and grille dampers closed too much; wrong size or
2

2
• Poor zone temperature control built into system, not accommodating type
:3

:3
shifting sun loads or occupancy
28

28
• Too much resistance in air distribution system
• Poor mixture of spaces on the same zone
1:

1:
• Dirty components, underdesigned ductwork, excessive ductwork,
• System imbalanced, too much or too little air in branch ducts and imperfect fittings
20

20
outlets near fan, or too little at end of duct runs
20

20
• Space thermostat incorrectly set, located, calibrated, or
• System misdesigned; duct sizing incorrect, pressure calculations malfunctioning
0/

0/
off
/3

/3
• Excessive duct leakage
,4

,4
• Occupant changes, HVAC system, architectural changes, internal
• End caps missing, disconnected ducts, access doors open, excessive
in

in
heat generation.
leakage at connections
ev

ev
II. PROBLEM: Too Much Air • Dirty, blocked off or clogged manual dampers, reheat coils, turning
K

vanes, grilles, ceiling diffusers, fire dampers

5,

5,

Possible Causes :
49

49

• Fan undersized, rpm low, wheel installed backwards or wrong

type, rotation backwards, wheel and inlet cone misaligned or
22

22

• Less resistance in system than design

• Ductwork oversized, less ductwork than design, system components’ incorrect gap, cutoff plate missing, manufacturer rating incorrect,
less resistance than design air starvation in suction side of fan
• Not all the system components installed Access doors open on • Underdesign of heating and cooling load or air volume e Manual
intake plenum volume dampers closed too much
• Coil bypass damper and face damper open • Fire dampers accidentally shut
PM

• Fan oversized, rpm high, wrong type, system resistance less than • Control dampers set incorrectly or malfunctioning PM
design • Filters dirty, clogged, blocked off, resistance rating too high, wrong
2

type, wrong size

:3

:3

• Over design of heating/cooling load or air volume Windows and

28

28

doors open in spaces • Terminal units in medium or high pressure systems in

1:

1:

• Control dampers not set properly or malfunctioning closed position, wrong size, wrong controls, set wrong or
malfunctioning
20

20

• Manual volume dampers open excessively

20

20

• Terminal units in medium or high pressure systems open, wrong • Excessive positive pressure in spaces, not enough return or exhaust
air being drawn out.
0/

0/

size, wrong controls, set wrong or malfunctioning

/3

/3

• Control of dampers, fans, or terminal units not working or • Imbalance in air distribution system; excessive dampering, wrong
,4

,4

incorrectly set procedures used in balancing, poor design

in

in

• Excessive negative pressure in spaces • Poor temperature control zoning

ev

ev

• Too much direct exhaust air or return air being drawn out of spaces • System incorrectly designed
K

K
5,

5,
49

49
CMYK

24 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
IV. PROBLEM: Fan Runs, Insufficient Air Flow VII. PROBLEM: Drafts

20

20
Possible Causes : Possible Causes :

20

20
• Excessive resistance in system • The speed of air is too high when it hits the occupants; not in the

0/

0/
/3

/3
• Wheel misaligned, improper wheel overlap and gap with inlet cone 25 to 50 fpm comfort range
,4

,4
can cause a sharp loss of air volume and cycling within the fan • The temperature of the air coming in contact with the occupants
in

in
• Bad fan discharges can wreak havoc with air quantities, causing is too high or low in conjunction with the air speed; should be in
ev

ev
statics, throbbing, pulsating, noises and duct wreckage. Poor 68 to 78 F range
K

K
discharges can be caused by: • Too much air at diffusers or grilles
5,

5,
• Undersized fan • Supply diffusers too small, deflection or throw incorrect
49

49
• Fan rpm low • Doors or windows open
22

22
• Low motor rpm • Horizontal and vertical temperature stratification in spaces;
• Wrong ratio of sheaves temperatures too high below ceiling or by outside walls and too
• Wheel rotating backwards low near floor or inside walls
• Wheel loose on shaft • Horizontal and vertical air speed stratification and currents;
• Wrong type wheel excessive air speeds near occupants.
PM

PM
• Wheel installed backwards. VIII. PROBLEM: Poor Temperature Control in Zones
2

2
V. PROBLEM: Fan Does Not Run, No Air Flow Possible Causes :
:3

:3
28

28
Possible Causes : • Too many rooms on one zone
1:

1:
• Room that has thermostat for zone not representative of all spaces
• Broken belts
20

20
on zone
• Blown fuses
20

20
• Spaces in zone don’t have homogeneous heating and cooling loads
0/

0/
• Thermal overloads in starter kicked out correlating with time and conditions
/3

/3
• No power • East. South, West, North solar load zones mixed together on same
,4

,4
• Bearings froze system
in

• Motor defective
in
ev

ev
• Perimeter and interior spaces mixed on same zone.
• Loose pulleys
K

IX. MISCELLANEOUS FAN PROBLEMS:

5,

5,

• Wheel housing jammed

49

49

• Motor heater overload kicked out Possible Causes :

22

22

• Wheel loose on shaft and spinning.

• Unbalanced wheels cause vibration, noises and premature wear of
VI. PROBLEM: Imbalanced System bearings and drives; wheels have to be dynamically balanced and
weights put on them for balance
Possible Causes :
• Misaligned or incorrectly tensioned belts on drives
• Major discrepancies between actual and design cfms. To locate, • Wheel installed backward
spot check:
PM

• A warped shaft caused by heat or in removing a wheel, causes PM

• Air Volume at outlets farthest from fan, at end of duct runs, nearest vibrations and premature bearing and drive wear
2

fan and midway in the duct system

:3

:3

• A shaft at an angle in the fan can be caused by heat or by replacing

28

28

• Total air flow or static pressure in main duct runs a wheel, causes vibrations and premature wearing of bearings and
1:

1:

• Total air flow at fan drives

20

20

• Suction and discharge pressures. • Fan cut off plate broken off.
20

20

References Washington D.C., USA.

0/

0/

4. Handbook of HVAC Design by Nils R. Grim & Robert Rosaler,

/3

/3

1. Air Handling System Design by Tseng-Yao Sun, McGraw-Hill.

McGraw-Hill.
,4

,4

2. Handbook of Air Conditioning and Refrigeration by Shan K. Wang, 5. ASHRAE Handbook 1996 HVAC Systems and Equipment by American
in

in

McGraw-Hill. Society of Heating, Refrigerating and Air Conditioning Engineers,

ev

ev

3. NAFA Guide to Air Filtration by National Air Filtration Association, Atlanta, USA.
K

K
5,

5,
49

49

CMYK

All About AHUs 25

22

22
CMYK

PM

PM
2

2
:3

:3
28

28
1:

1:
Fan Laws

20

20
For the same fan-duct system operating at different speeds, The fan power ratio is equal to the cube of the speed

20

20
if the difference in air density is negligible, the volume flow ratio :

0/

0/
rate is proportional to the speed ratio :
/3

/3
3. Bhp2 = rpm2 3
,4

,4
1. cfm2 = rpm2 Bhp1 rpm1
in

in
cfm1 rpm1
ev

ev
Where subscripts 1 and 2 indicate the original and changed
K

K
The total pressure increase ratio is equal to the square of operating conditions.
5,

5,
the speed ratio :
49

49
2. P2 = rpm2 2
22

22
P1 rpm1

Airflow Formulas Used in Air Filtration

PM

PM
1) To calculate volume (CFM) from velocity (FPM): 7) To calculate filter media velocity in FPM:
CFM = FPM × Ft. 2 FPM = CFM / Media Area (Ft.2)
2

2
:3

:3
2) To calculate velocity (FPM) from volume (CFM): Where :
28

28
Af = Filter face area
1:

1:
FPM = CFM/Ft. 2

CFM = Volume air in cubic feet per minute

20

20
3) To calculate velocity (FPM) from velocity pressure
20

20
(PV): CFMS = System CFM
0/

0/
FPM = 4005 PV FPM = Velocity of air in feet per minute
/3

/3
PV = Velocity pressure in inches water gauge
,4

,4
4) To c a l c u l a te vo l u m e ( C FM ) f ro m ve l o c i t y
in

in
pressure(PV): PV = Total system pressure minus static pressure
ev

ev
CFM = (4005 PV) × Ft.2 4005 = A constant
K

Ft.2 = (1) Face area of filter or filter bank

5,

5,

5) To calculate velocity pressure (P V) from volume

49

49

(CFM): (2) Area of duct cross-section

22

22

PV = [(CFM / Ft.2) / 4005]2 FFV = Filter face velocity

Nf = Number of filters
6) To calculate panel filter face velocity in CFM:
FFV = [CFMS / Nf) / Af]
PM

Useful Conversions
PM
2

To convert From To Multiply by

:3

:3
28

28

velocity fps m/s 0.30480

1:

1:
20

20

velocity fpm m/s 0.0050800

20

20

velocity mph m/s 0.447040

0/

0/
/3

/3

velocity m/s fps 3.28084

,4

,4

velocity m/s fpm 196.850

in

in
ev

ev

velocity m/s mph 2.23694

K

K
5,

5,
49

49
CMYK

26 All About AHUs

22

22
 CMYK
PM

PM
2

2
:3

:3
28

28
1:

1:
Useful Conversions contd..

20

20
To convert From To Multiply by

20

20
0/

0/
pressure psi Pa(N/m2) 6894.76
/3

/3
,4

,4
pressure psf Pa(N/m2) 47.8803
in

in
pressure ft of water (4°C) Pa(N/m2) 2988.98
ev

ev
pressure in. of water (4°C) Pa(N/m2) 249.082
K

K
5,

5,
pressure in. of Hg(15.6°C) Pa(N/m2) 3376.85
49

49
pressure Pa(N/m2) psi 0.000145038
22

22
pressure Pa(N/m2) psf 0.0208854
pressure Pa(N/m2) ft of water (4°C) 0.000334562
pressure Pa(N/m2) in. of water (4°C) 0.00401474
pressure Pa(N/m2) in. of Hg (15.6°C) 0.00029613
volume flow rate cfm m3/s 0.000471947
PM

PM
volume flow rate cfs m3/s 0.02831685
2

2
:3

:3
volume flow rate gpm m3/s 0.0000630902
28

28
volume flow rate gpm l/s 0.0630902
1:

1:
volume flow rate m3/s cfm 2118.88
20

20
20

20
volume flow rate m3/s cfs 35.3147
0/

0/
volume flow rate m3/s gpm 15,850.3
/3

/3
volume flow rate L/s gpm 15.8503
,4

,4
in

Fan Connections in
ev

ev
K

Fan Inlet Connections Fan Outlet Connections

5,

5,
49

49
22

22
PM

PM
2

2
:3

:3
28

28
1:

1:
20

20
20

20
0/

0/
/3

/3
,4

,4
in

in
ev

ev
K

K
5,

5,
49

49

CMYK

All About AHUs 27

22

22