BLUE STAR AIR HANDLING UNIT

AIR HANDLING UNITS

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BLUE STAR AIR HANDLING UNIT

THE LEADERS IN COOLING

Blue Star is India’s largest central air conditioning and commercial refrigeration company, with over seven decades of experience in
providing expert cooling solutions. It has offices across India, UAE, Malaysia, Qatar and Oman, 5 modern manufacturing facilities,
around 2500 employees and a turnover of over USD $530 million. Alliances and partnerships with leaders in global technology have
further enhanced Blue Star’s capability in providing advanced cooling solutions for diverse needs.

Blue Star offers a range of air conditioning products that encompasses Screw Chillers, Scroll Chillers, Air Handling Units, Fan Coil
Units, Packaged Air Conditioners, Ducted Splits and VRF Systems apart from room air conditioners such as Split, Window, Verticool
and Cassette Air Conditioners. Refrigeration products include Water Coolers, Deep Freezers and Water-Cooling solutions specifically
designed to cater to the unique requirements of India, Middle East, Africa, SAARC, ASEAN and Pacific Islands markets.

A wide range of models is available in each product category to ensure that the air conditioning system design is implemented without
any compromise. All the products are energy efficient and come with a host of distinctive features. Every Blue Star product is a result of
robust R&D, a strong understanding of design and superior manufacturing processes. These core attributes have made Blue Star the
preferred cooling solution provider.

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BLUE STAR AIR HANDLING UNIT

GLOBAL PRESENCE
Blue Star’s international business consists of AC&R product exports to the Middle East, Africa, SAARC,ASEAN and Pacific Islands
regions, with steady progress also being made in developing the other international markets. In addition, the Company also participates
in international projects managed by the Company’s joint ventures in Qatar, Oman and Malaysia.

New opportunities are being identified for AC&R products, MEP projects, after-sales service as well as system integration and agency
businesses in global markets.

CUTTING-EDGE R&D
Blue Star’s innovations are bourn out of the high-end R&D establishment that has been painstakingly put together over decades with
the brightest brains and the latest equipment in place.

Recognized by the Department of Science and Industrial Research (DSIR) – Ministry of Science and Technology, Government of India,
Blue Star’s R&D has enabled the Company to file more than 25 patents and win many prestigious innovation awards.

WORLD CLASS TESTING FACILITIES

Blue Star’s infrastructure for conducting various performance tests on new products is one of the largest in India, ensuring that every
product and technology is tested vigorously before being productionised. Blue Star has 6 Psychrometric, 2 condensing and 2
Environmental test labs.

Blue Star's R&D labs at Thane and Dadra have been certified by Intertek, Sweden to carry out safety tests for HVAC products as per
the International Electro technical Commission Standards. Intertek is a global leader in safety testing and certification for regulatory
approval.
Also, the National Accreditation Board for Testing and Calibration Laboratories (NABL) has conferred Certificate of Accreditation to
Blue Star Laboratories located at Thane and Wada, India in accordance with the Standard ISO 17025: 2005.NABL is a signatory
member of APLAC and International Laboratory Accreditation Cooperation (ILAC).

Products designed are also subject to various reliability tests before they are cleared for manufacturing. These include endurance,
vibration and shock tests along with life cycle and ageing tests to rigorously test design reliability. All Blue Star products are designed
to perform under tropical conditions such as high ambient, high humidity, extreme voltage condition and fluctuations.

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BLUE STAR AIR HANDLING UNIT

ADVANCED PSYCHROMETRIC TEST LAB

Blue Star factories have a modern Psychrometric Test Lab that can simulate and test products under various conditions. All machines
manufactured at our factories are rigorously tested for various parameters before dispatch. Customers too can witness actual
performance tests conducted on the products before dispatch of their machines, making Blue Star one of the few companies in the air
conditioning industry offering this facility.

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BLUE STAR AIR HANDLING UNIT

WORLD CLASS MANUFACTURING

Blue Star’s manufacturing strength is spread across five state-of-the-art manufacturing facilities. Blue Star’s commercial and residential
AC units are manufactured at the modern factories at Wada, Dadra and Himachal Pradesh. Set up to International Standards, the
products manufactured at these ISO 9001-2008 certified factories are exported to various countries across the globe.

The factories are highly productive, automated and flexible. They are also efficient in manufacturing the setup of heat exchange coils
and advanced chillers. In addition, these factories have modern sheet metal fabrication units with Amada punching and bending
machines.

ENSURING AN EXCELLENT FINISH

Blue Star's production facilities use raw materials that are of the highest quality, including corrosion resistant, galvanized steel for
enhanced life and rust protection. The equipment used to process the steel Includes CNC machines such as the Amada punch press,
hydraulic press, specialized microprocessor-based protection and resistance welders. All these machines ensure superior quality in
cabinet fabrication to tight tolerances.

All products are powder coated by specialized process equipment from Nordson of the USA on fully conveyorized lines. They are fitted
with electro-mechanical oscillators that ensure an even powder coating. A'smart spray' mechanism senses movement of the conveyor
and geometry of the component to adjust the powder flow.

Blue Star is equipped with a high-tech coil manufacturing setup using imported Burr Oak machines that can manufacture high
efficiency plain coils as well as enhanced split fins for superior heat transfer. The copper tubes are then processed by a bank of PLC-
Controlled Burr Oak machines that ensure perfect bonding between the copper tubes and fins for superior performance. The coils are
then tested for fine leaks with ultra-sensitive electronic leak detectors to enhance reliability.

The entire AHU range is manufactured with robust manufacturing practices and quality processes laid down by Blue Star. And is
subject to QC testing at the factory for all critical parameters such as CFM and static pressure, casing leak, current, voltage and
vibration.

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BLUE STAR AIR HANDLING UNIT

CERTIFIED FOR EXCELLENCE

Blue Star’s production processes and QC have resulted in international recognition of the quality and reliability of Blue Star products
and their performance.

ISO 9001-2015 Quality Management System Standard Certification for Design, Development& Manufacturing of Air Conditioning and
Refrigeration Equipment.

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BLUE STAR AIR HANDLING UNIT

Eurovent Certification for Air Handling Units – Mechanical and Performance Characteristics.

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BLUE STAR AIR HANDLING UNITS

Air Handling Units are devices which can carry out air conditioning processes such as Ventilation, Cooling, Heating, Humidification, De-
humidification, Filtration, Heat recovery, etc. Blue Star Double Skin AHUs are engineered and manufactured with innovative technology
to deliver an energy efficient Air Handler with Optimum design, Superior quality and Reliable performance. A typical Air handling Unit
schematic is shown below.

Blue Star EDSA series Air Handling Units are Eurovent Certified according to EN 1886 and EN 13053. Our AHUs are designed to
meet the Indoor Air Quality requirement as per ASHRAE 62. We have a wide range of AHUs for use in various applications from small
offices to larger industrial applications. Common to all items in the range is that the system and components have been developed to
satisfy stringent demands of low energy consumption. Heat exchangers, motors and fan units have all undergone extensive testing,
both in laboratory and out in the field, in order to comply with current and future demands for low energy consumption.

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BLUE STAR AIR HANDLING UNIT

AHU FEATURES
 Suitable for both indoor and outdoor installation.
 EDSA units are Eurovent Certified & NDSA series are non-certified.
 Eurovent Certified Selection Software.
 Heating, Cooling, Humidification, De-humidification, Extensive range of Filters and Various Heat Recovery sections.
 Available in 41 different models with Air Flow Rate range of 1,000 to 76,000 CFM.
 EDSA series are available in 50 mm panels, whereas NDSA series are available in both 25 mm and 50 mm.
 Component Flexibility.
 Modular Construction.
 Energy Efficient.
 Easy for installation and Better Serviceability.
 Low Noise and Vibrations.
 High Indoor Air Quality.
 Can handle Static Pressures up to 2300 Pa.
 Factory Acceptance Test and Performance Test.

COMPONENTS OF AHU
 Fans: A variety of fans can be offered based on the requirement - Belt driven DIDW centrifugal forward curved/Backward
curved fans, Centrifugal plug fans, EC fans.
 Motors: IP 55 Class F insulated Motors with IE2, IE3, IE4 efficiency.
 Supply and Extract Filters: Units are offered with high quality and low pressure drop filters of different particulate
efficiency.
 Heat transfer coils: Copper tube aluminum finned heat transfer coils available in multiple rows deep and are designed to
give certified performance output for cooling, heating and recovery applications.
 Tightness and Corners: Framework of airtight, elegant and sturdy extruded aluminum hollow profile with polyamide
thermal break profile having glass filled nylon corners and spacers.
 Dampers: Low-leakage extruded aluminum/GI dampers suitable for manual or motorized operations.
 Base Frame: Made of strong galvanized steel with lifting provision, as an option we have aluminum base frame.
 Inspection doors/handles: Adequate sized inspection doors are provided in each section fitted with high quality
comfortable handles.
 Heat Exchangers: High quality and energy efficient heat exchangers are available – Heat Recovery Wheels, Plate Heat
Exchangers, Heat Pipes or Run around Coils.

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BLUE STAR AIR HANDLING UNIT

AHU APPLICATIONS
Blue Star AHUs are designed in modules which can be configured for different applications to make up the heart of any air conditioning
system. The flexibility makes it possible to optimize the air handling unit for specific requirement.
 Comfort Solutions: Simple project implementation for expansion of existing premises or new buildings. Simplifies
selection plus planning and includes smart solutions for easier installation.
 Compact Solutions: Extreme space saving solutions and new connections for units that can also be split. Completely
adaptable to satisfy all new demands. Compact air handling units are easier to transport and handle at the construction
site.
 Flexible Solutions: Flexible solutions with heat recovery and intelligent control functions that are easily adapted to suit
current needs of different recovery system and configurations.
 Industrial Solutions: Air humidifiers can be installed in air handling units which makes the units suitable for air cooling,
water spray humidifier and scrubber applications.
 Clean Room Solutions: Clean rooms can encompass numerous applications, everything from operating theaters to
laboratories. Our air handling units can satisfy all requirements relating to healthcare, whether these have to do with air
cleanliness, noise levels or demand control.

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BLUE STAR AIR HANDLING UNIT

CHARACTERISTICS OF BLUE STAR AHUs

Mechanical& Thermal performance of AHU housing is tested in Eurovent accredited laboratory as per EN 1886 with the following
results.

Mechanical Strength: D1
Air Leakage: L1
Filter Bypass leakage: F9
Thermal Transmittance: T3
Thermal Bridging: TB2
Acoustic Insulation: @ 15 dbA reduction.

The performance of AHU is tested in a Eurovent accredited laboratory in accordance with EN 13053. Tests are carried out for Air Flow
Rate – Static Pressure data – Power consumption, Heat Recovery, Cooling duty, Heating duty and air side & water side pressure
drops.

BLUE STAR AHU RANGE

Blue Star’s AHUs come in variety of forms to suit any installation, ensuring freedom and flexibility in design. The range includes
Eurovent and Non-Certified AHUs.

AHU NOMENCLATURES
EDSA- Eurovent Certified Double Skin Air Handling Unit
NDSA- Non - Certified Double Skin Air Handling Unit
DCW/XS – Double Skin Ceiling Suspended Water Coil/DX Coil Standard Air Handling Unit

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BLUE STAR AIR HANDLING UNIT

QUICK SELECTION OF EDSA AHUs

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MECHANICAL PERFORMANCE OF AHU CASING – EN 1886

Casing Strength
Air Handling unit casings are categorized in to classes according to below table.

Casing Class Maximum relative deflection (mm/m)

D1 4
D2 10
D3 Exceeding 10
Note: Leakage test shall be done after casing strength test.
Class D1 and D2 casings shall be designed and selected so that the maximum deflection of any span of the panels or/and frames does
not exceed the limits in above table. The casings of class D1, D2 and D3 have to withstand the maximum fan pressure (not shock
pressure) at the selected design fan speed. No permanent deformation (hysteresis maximum ±2 mm/m frame/panel span) of the
structural parts (structures and supports) or damage of the casing may occur.

Test Criteria Kind of casing

Model Box Real Unit (RU)
(M)
Deflection ± 1000 Pa Normal operating conditions at selected design fan speed.
Withstand maximum fan pressure ± 2500 Pa Maximum fan pressure at selected design fan speed.

Casing Air Leakage

Air leakage tests shall be done after the strength test. Leakage test shall be performed at both negative pressure (-400 Pa) and positive
pressure (700 Pa).

Testing under negative pressure

Leakage class Maximum Leakage rate (f400) in Filter Class (EN 779)
of casing l X s-1 X m-2
L1 0.15 Superior to F9
L2 0.44 F8 to F9
L3 1.32 G1 to F7

Unless otherwise specified, the applicable rate shall be a function if the efficiency of the air filters within the air handling unit. Where
there is more than one stage of air filtration, the classifications shall be based on the efficiency of the highest grade of filter.

In the case of units tested at a pressure deviating from 400 Pa, the measured leakage rate shall be converted in to a value at reference
pressure, using the following formula:

f400= fm (400/test pressure)0.65

where:
fm is the measured leakage rate at the actual test pressure.
f400 is the converted leakage rate at 400 Pa.

Testing under positive pressure

Leakage class of Maximum Leakage rate (f700) in
casing l X s-1 X m-2
L1 0.22
L2 0.63
L3 1.90
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BLUE STAR AIR HANDLING UNIT

In the case of units tested at a pressure deviating from 700 Pa, the measured leakage rate shall be converted in to a value at reference
pressure, using the following formula:

f700= fm (700/test pressure)0.65

where:
fm is the measured leakage rate at the actual test pressure.
f700 is the converted leakage rate at 700 Pa.

Filter Bypass Leakage

Air bypass around filter cells will decrease the effective efficiency of the filter, especially a high efficiency one, because the bypass air is
not filtered. In addition, any inward leakage through the casing downstream of the filter has the same effect. Therefore, for filters
located upstream of the fan, the air tightness and area of the casing between the filter and the fan are factors that can affect the filter
bypass leakage rate.

Below table gives the acceptable filter bypass leakage rate, related to different filter classes, as percentages of the specified or nominal
air flow rate of the air handling unit to be tested. If the filter is upstream of the fan, leakage of the sections between the filter and fan are
deemed to be included in specified value. In case of downstream filters, the specified values are for the bypass around the filter only.

Filter Class G1 to F5 F6 F7 F8 F9
Maximum filter bypass leakage rate 6 4 2 1 0.5
k in % of the volume flow rate

The acceptable filter bypass leakage rate qva is specified by the formula:
qva= k X qvnom / 100
where:
qvnom is the air flow rate of the filter section.
K is the filter bypass leakage rate, in percent of specified or nominal air flow rate.

If two or more filter sections are provided within the air handling unit, the filter bypass leakage shall be tested separately for each filter.

THERMALPERFORMANCE OF AHU CASING – EN 1886

This test procedures provides the means for classifying the thermal transmittance of an air handling unit using a test enclosure with
standard construction features. The test is also used to provide a measure of thermal bridging associated with the structural design.

Thermal Transmittance
The thermal transmittance U (W X m-2 X K-1) shall be determined when the steady state temperature difference of 20K. Under these
conditions, the U values shall be classified in accordance with below table. The area used for the purpose of calculating U value shall
be that of the external surface area of the casing (without a base frame and a canopy).

Class Thermal transmittance (U) in

W X m-2 X K-1
T1 U ≤ 0.5
T2 0.5 < U ≤ 1.0
T3 1.0 < U ≤ 1.4
T4 1.4 < U ≤ 2.0
T5 No requirements

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Thermal transmittance is calculated using below formula.

U = Pel / A X ∆tair
where:
Pel is the electrical power input for heater and circulating fans.
A is the external surface area.
∆tair is the air to air temperature difference. ∆tair= ti – ta
ti is the mean internal air temperature.
ta is the mean external air temperature.

Thermal Bridging
Under the test conditions, when the mean temperature difference between internal and external temperature is established at 20 K, the
lowest values of temperature difference between any point on the external surface and the mean internal air temperature shall be
established. The ratio between the lowest temperature difference and the mean air to air temperature difference determine the thermal
bridging factor.

Determine the thermal bridging factor kb as follows,

kb = ∆tmin / ∆tair
where:
∆tmin is the least temperature difference, ∆tmin = ti – tsmax
∆tair is the air to air temperature difference ∆tair=ti – ta
ti is the mean internal air temperature.
ta is the mean external air temperature.
tsmax is the maximum external surface temperature.

The thermal bridging factor kb of the casing shall be graded in accordance with below table.

Class Thermal bridging factor (kb)

TB1 0.75 < kb< 1.00
TB2 0.60 ≤ kb< 0.75
TB3 0.45 ≤ kb< 0.60
TB4 0.30 ≤ kb< 0.45
TB5 No requirements

BLUE STAR AHU TECHNICAL SPECIFICATIONS – EN 1886

Mechanical Strength D1 D2 D3
(mm x m-1) 4 10 >10

L1 (f400) L2 (f400) L3 (f400)

Casing Air Leakage
(l x sˉ1 x mˉ2) 0.15 0.44 1,32
L1 (f700) L2 (f700) L3 (f700)
0.22 0.63 1,90
Filter Bypass Leakage F9 F8 F7 F6 G1-F5
(%k) 0.5 1 2 4 6
Thermal T1 T2 T3 T4 T5
Transmittance
(W x mˉ2 x Kˉ1) U < 0,5 0.5 < U ≤ 1.0 1.0 < U ≤ 1.4 1.4 < U ≤ 2.0 2.0 < U
TB1 TB2 TB3 TB4 TB5
Thermal Bridging 0.60 ≤ kb <
0.75 < kb < 1.00 0.45 ≤ kb < 0.60 0.30 ≤ kb < 0.45 kb < 0.3
0.75
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AHU CASING/CABINET CONSTRUCTION

Housing of Blue Star AHUs are made of double skin construction complying with Eurovent Standard for mechanical characteristics as
per EN 1886. The metal enclosure that covers all the components contained in the AHU is sturdy and has no protruding parts to disturb
the overall look of the unit. Air handling units have a frame composed of an extruded aluminum section that outlines the equipment
edges perfectly, resulting in a solid, robust and attractive overall look. These aluminum extruded sections are with or without Polyamide
Thermal break profile. EDSA series AHUs are with Thermal Break profile, whereas it is optional for NDSA series AHUs.

The sections joined by injection-molded glass reinforced plastic angle cleats. In the larger sizes, the sections are joined together by
angle cleats made from engineered plastics. The assembly is anchored by slot screws, obtaining a solid, sturdy structure.

The unit enclosure is made up of sandwich panels comprising two pieces of sheets one inside the other. Outer Casing of AHU is made
of 0.6 mm thick Pre-coated GSS with 40-micron PVC protection film and Inner Casing is made of 0.6 mm thick Plain GSS/Aluzinc, as
Standard for both EDSA and NDSA series AHUs.

As Standard, NDSA series are with 25 mm thick panels and EDSA series are with 50 mm thick panels. Insulation between the skins is
machine injected CFC free Polyurethane foam having density 38 +/-2 kg/m3 and thermal conductivity of 0.022W/m K. Please refer
below Summary table for Standard Casing Specification.

Outer Skin Inner Skin Thermal Break Panel Insulation

Series
Material Thickness Material Thickness Profile Thickness Material Density
EDSA Pre-coated GSS 0.6 mm Aluzinc 0.6 mm Yes 50 mm PUF 38+/-2 kg/m3
NDSA Pre-coated GSS 0.6 mm Aluzinc 0.6 mm No 25 mm PUF 38+/-2 kg/m3

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BLUE STAR AIR HANDLING UNIT

Cabinet construction of AHU reduces the sound level significantly. And it is maintenance friendly through easy access to all the
components. Panels can be removed from all the sections without compromising the rigidity of AHU, which is ensured by Aluminum
frame. The panels are screwed to the structure using soft food grade gasket to make it leak proof. Air tight access doors/panels with
die cast Zinc hinges are provided for access to various sections for maintenance. Access doors are with double wall Inspection Window
of 200 mm diameter and robust glass filled Nylon handles operational from both sides with optional locking arrangement. Each section
is provided with duly wired Marine Lights and on/off switch mounted on wall of the unit.

The entire housing of the AHU is mounted on Rolled formed GSS channel frame work with provision for handling the units at site.

Drain pan is constructed of 18G 304 Stainless Steel with dual slope to facilitate immediate discharge of condensate. Specially designed
drain pan with all round edges allow complete cleaning and avoid microbial growth as per ASHRAE 62-1992 standard. The drain pan is
insulated externally with 19 mm thick Nitrile Rubber and extended at least 300 mm beyond the coil. Necessary arrangements are
provided to slide the coil in the drain pan.

Casing/Cabinet Optional features

 Outer Skin: 0.8/1.0 mm Pre-coated GSS, 0.8 mm Aluzinc and 0.6/0.8/1.0/1.2 Stainless Steel.
 Inner Skin: 0.8/1.0/1.2 mm Plain GSS, 0.6/0.8/1.0 Pre-coated GSS,0.8 mm Aluzinc, 0.8/1.0/1.2 mm Aluminum and
0.6/0.8/1.0/1.2 Stainless Steel.
 Panel Insulation Material & Density: Fiberglass (48 kg/m3) and Rockwool (96 kg/m3 & 144 kg/m3).
 Thermal Break Profile for NDSA series AHUs.
 50 mm thick panels for NDSA series AHUs.
 Drain Pan: 0.8/1.0 mm Stainless Steel and 1.6 mm Aluminum.

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MODULAR JOINING
Our newly developed section joiners are with Ultra low leakage, maintains Thermal Bridging. AHUs in modules are easy to handle
during transportation as well as installation.

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BLUE STAR AIR HANDLING UNIT

AIR INLET SECTION/MIXING SECTION/FREE COOLING SECTION

AHUs can be supplied with Air Inlet Section, Mixing Box Section or Free Cooling section as per requirement. Air inlet section is used
when the AHU is with 100% Fresh Air or 100% Return Air, section will be with Damper, with Flange for duct connection or with Louver.
Dampers are constructed from high quality airfoil design Aluminum/GI extrusion and are suitable for manual or motorized operation. In
Mixing section, a certain amount of Fresh Air is mixed with the Return Air, fulfilling the fresh air requirement of the conditioned space.
Both FA and RA opening are with Control dampers. Free Cooling sections are used to regulate the volumes of Fresh Air, Return Air
and Exhaust Air. When the enthalpy of the outside air is less than the enthalpy of re circulated air, the mixture of outside air and re
circulated air is controlled to achieve free cooling. Damper Motors/Actuators and linkages to be done at site by the Contractor.

COMPONENTS OF BLUE STAR AIR HANDLING UNIT

FILTER SECTION

Filter plays a major role in maintaining good indoor air quality. Air contains numerous foreign substances caused by natural processes
(wind erosion, sea evaporation, volcanic eruptions, etc.) and by human activity (combustion). Atmospheric dust is a mixture of fog,
combustion gases, fine dry particles and fibres. Air testing normally indicates the presence of soot and smoke, quartz, soil, residue
from decomposed animals and vegetables, organic substances in the form of cotton and plant fibres, and metal fragments. The air also
contains other organisms such as microorganisms, spores and pollen.

Air contains particles with a thickness of up to 0.01 microns and other particles with a thickness similar to fibres, leaves, etc. Dust is
generally understood to mean particles under 100 microns. The particle size distribution in atmospheric dust can be measured in
several ways. Traditionally, a variety of measurement methods had been used to determine the efficiency of the different types of filters
and no classification system combining the various criteria in use existed. The first version of the United Standard EN 779 was issued
to unify the classification criteria for all filters with an initial efficiency with atmospheric dust less than or equal to 98%. (Group G –

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Coarse filters, Group F – Fine filters). Later in 1998 the first version of United Standard EN 1822 unifying the classification criteria for
HEPA and ULPA absolute filters was published. The initial efficiency of these filters with atmospheric dust was greater than 98%.

The standard range for Filters in Blue Star AHU includes three air filtering sections which combined with the wide variety of filtering
materials covering an extensive range of possibilities in filtering efficiency. The media is thermally bonded with progressive density to
have high dust holding capacity and low initial pressure drop. All Filters are in accordance with ASHRAE 52.2 and EN 779 standards.
All filters are easily accessible for maintenance.

PRE-FILTERS
Blue Star AHUs are supplied with non-woven synthetic media pre-filters.
Efficiency: G4 (EU4) – 90% @ 10 microns.
Filter Thickness: 50 mm standard. 100 mm is optional.
Frame Material: Aluminum as standard. SS/GI/MS are optional.
Media Supporter: Aluminum Mesh/HDPE Mesh as standard. GI Mesh/GI Rod are optional.
Filters are tested as per ASHRAE 52.1 and EN-779.

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FINE-FILTERS
Variety of Fine Filters are available. All are with Non-woven synthetic media as standard.
Bag Filters are available in Box type & Flange type.
Efficiency: F7 (EU4)–99% @ 3 microns, F8 (EU8)– 70% @ 0.3 microns& F9 (EU9) – 75% @ 0.3 microns.
Filter Depth: 300 mm standard. 500 mm is optional.
Frame Material: Anodized Aluminum as standard. SS/GI/MS are optional.
Media Supporter: Aluminum Mesh/HDPE Mesh/GI Mesh as standard. GI Rod/Aluminum foil/Hotmelt are optional.
Filters are tested as per ASHRAE 52.1 and EN-779.

HEPA-FILTERS
Filter Media – Micro Fiber Glass Paper (Deep pleated panel type) as standard.
Bag Filters are available in Box type, Flange type& Channel type.
Efficiency: H13 (EU13)- 99.97% @ 0.3 microns. H14 are also available.
Filter Depth: 300 mm standard.
Frame Material: Aluminum as standard.
Media Supporter: Aluminum Foil as standard.
Filters are tested as per EN 1822-4/5.

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Filter Section Optional features

 Magnehelic Manometer.
 Differential pressure switches.
 Inspection Window and Marine light.
 Stainless Steel frames for filters.
 Fire retardant media for pre-filter.
 Mini pleat fine filters.
 High Efficiency ULPA Filters.

COIL SECTION
Coils are critical component of Air Handling Unit, which are used for Cooling, Heating and Mechanical de-humidification processes.
Their performance has strong bearing on the ultimate indoor environmental conditions, which in turn, has significant impact on the
Indoor Air Quality. We are manufacturing Chilled/Hot Water coils and Refrigerant Direct Expansion coils for our AHUs. Performance of
Coil is in accordance with EN 1216 standard with a maximum tolerance of 5%. Also, Capacity of the coil, water pressure drop and
selection procedure are in accordance with ARI standard 410.

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Both Water and Gas coils are constructed of 12.7 mm outer diameter Copper tubes having minimum wall thickness of 0.4 mm with
waffle/ripple Aluminum fins having 0.15 mm thickness firmly bonded to Copper tubes assembled in 1.5 mm thick Zinc coated Steel
frame. Mechanical expansion of tubes assures tight bonding between tubes and fins for better heat transfer. Fin spacing is 10 to 12 fins
per inch (4 to 5 fins per cm). Coils are provided with Copper header and MS adaptor.

Coils are pitched in the unit casing for proper drainage. Cooling coil section is provided with insulated drain pan in order to hold and
remove the condensate formed during dehumidification. Coils are assembled in slide rails for easy removal for maintenance. AHUs will
be supplied with Manual Air Vent at high point in the cooling/heating coil and drain plug in the bottom of the coil.

Coils are designed based on the maximum utilization of cross sectional area to achieve the most efficient heat transfer. Recommended
maximum air face velocity across cooling coil is 2.5 m/s. whenever an application requires face velocity higher than recommended
value or when the humidity is high, there are chances of moisture carryover. To prevent the same, our AHUs can be supplied with
Droplet Eliminator made of PVC, which avoid the moisture carryover. In such AHUs, drain pan will be extended to cover the bottom of
Droplet Eliminator for the collection of condensates.

Water Coils are factory tested at 300 psig air pressure under water and Dx coils are tested at 450 psig.

Coil Section Optional features

 Tubes: Plain Copper tubes with 0.35/0.5 mm wall thickness&5/8-inch OD Plain SS tube with 0.5 mm thick wall.
 Fins: Pre-coated Aluminum fins with 0.15 mm thickness & Copper Fins with 0.15 mm thickness.
 Heresite coating for coil.
 1.6 mm thick Stainless-Steel Coil frame – SS304/316/316-L
 Droplet Eliminator – PVC, Powder coated GI or SS.

HUMIDIFER SECTION
Blue star AHUs can be supplied with two different types of Humidifiers such as Panel Humidifiers and Water Spray Humidifiers. In both
cases, the units are adiabatic humidifiers. This section is available with NDSA series AHUs only.

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Panel Humidifiers
Panel Humidifiers are composed of an enclosure with humidifier panel, Stainless Steel drip pan at bottom, water manifold at the top
and submersible electrical pump. Water is pumped through pipes by using pump and is distributed vertically downwards by gravity. As
the air flows by the panel horizontally through the spaces provided, turbulent flow conditions are established and thereby resulting in
efficient heat and moisture transfer. Humidifier panels are made of two different types of materials.

1. Cellulose – Humikool – with Chemical additives allowing it to absorb water without affecting its stiffness.
2. Fiberglass – Hu-Cell – with structural additives for stiffening.
Cellulose Humidifiers panels can be supplied with 3 different thicknesses,
a. 150 mm thick with Saturation Efficiency of 75%
b. 200 mm thick with Saturation Efficiency of 92% and
c. 300 mm thick with Saturation Efficiency of 95.5%

End plates are made of GI as standard and SS can be given as optional. Standard drain pan is 1.6 mm thick Aluminum sheet and
0.8/1.0/1.2 mm thick Stainless-steel drain pan is optional.

Water Spray Humidifiers / Air Scrubbers

Blue Star AHUs can be equipped with Water spray humidifiers which mainly serve for Adiabatic cooling, humidifying and air washing.
This section houses Spray nozzles, heat exchanger media, water collecting tank and droplet eliminator to prevent entrainment of water
particles. System require a water circulating pump (not in our scope of supply) which re circulate water at a rate higher than the
evaporation rate. Water tank is equipped with drain connection, overflow outlet, water feed with float valve and suction connection with
screen.

ELECTRIC HEATER SECTION

AHUs can be supplied with Electric Heater having Capacity as indicated in the schedule. Heaters can be either strip or tubular type.
Electric heaters are in accordance with IEC standard. Heating elements are constructed from 80/20 Nickel chrome resistance wire,
which is connected to terminal pins and centered in Stainless Steel grade 304L sheath metal tubes.

Step Controls and Thyristor controls are optional features.

UVC EMITTERS
The specified product will be packaged with a plan and drawing for the installation of the lamp assemblies as supplied by
manufacturer’s installation manual indicating orientation (upstream, downstream or both sides of the coil) of the installation. Each UV-C
lamp will be attached to a reflector that will reflect the UV-C energy in order to effectively irradiate the HVAC coil surface and drain pan.
The reflector will be built from a high UV reflectivity material capable of withstanding air velocities of up to 2000 ft/min. without
excessive noise, wobble, or vibration. The electronic power supply will be mounted on a rigid surface outside of the AHU in an
adequate enclosure protecting it from moisture and humidity.

FAN SECTION

Fan
Blue Star Air Handling Units are supplied with highly energy efficient Double Inlet Double Width belt driven Centrifugal Fans, as
standard. They are tested and certified for air and sound performance as per AMCA 210-85. All Impellers and fan shafts are statically
and dynamically trim balanced to ISO 1940 and AMCA 204/3 – G4.5 standard. Centrifugal fan Impellers can be Forward Curved,
Backward curved or Airfoil profiles depending on the requirements. Forward curved fans are used for low static requirement and
backward curved or backward curved airfoil fans are used for high static and high efficiency requirements.

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Fan casing is made of Galvanized Steel. Impellers of Forward curved, Backward curved and Airfoil fans are manufactured from
Galvanized Steel, heavy gauge sheet steel and Mild steel respectively. Impellers are mounted on a solid shaft made of C40 Carbon
Steel with corrosion protection coating, supported to housing with angle iron frame and heavy-duty ball bearings/pillow block bearings.
Fan and Motor assembly are mounted on a common extruded Aluminum base mounted on deep section extruded Aluminum or heavy
gauge GSS channel inside AHU housing on anti-vibration mounts. The mounts can be either spring or turret depending on the fan
frame size. Fan outlet is connected to casing with fire retardant fabric flexible connection for ensuring low noise operation. Wire guards
are provided at fan section access door.

Motor and Drive

Fan Motors are Totally Enclosed Fan Cooled (TEFC), Energy Efficient (IE-2), IP 55 protected and class F Insulated Squirrel Cage
Induction Motors. Motors are specially designed for quite operation. Motors are mounted inside the AHU casing on slide rails for easy
belt tensioning. Complete Fan-Motor drive assembly is mounted on floating sub-base with Anti-vibration mounts. Motor rating and
operating characteristics are in accordance with IEC 60034-1 and IEC 60085. As standard, all fans are belt driven with a set of fixed
pitch pulleys and matching belts. Belts are oil-resistant type.

Fan Section Optional features

 Plug Fans with AC Motor.
 EC Fans with Motor.
 Air Flow Switches.
 Premium and Super Premium highly efficient Motors – IE3 and IE4.
 Flame Proof Motors.
 Built in thermistor for thermal protection.
 VFD Compatible Motors.
 Dual Speed Motors.
 Variable Pitch Pulley.
 Standby Motors with manual change over.

HEAT RECOVERY SECTION

The increased supply of Outdoor air needed for ventilation to achieve acceptable Indoor Air Quality levels recommended in ASHRAE
standard 62 significantly increases the cooling and heating loads that the HVAC Equipment needs to handle, resulting in higher initial
and operating cost. To compensate the same, we are designing our AHUs/FAHUs with Heat Recovery system to reduce the energy
consumption associated with the treatment of the supply air. We can define Heat Recovery in brief as the process where the energy
held by the expelled air is transferred to fresh air, it is essential that the fresh air doesn’t mix with the dirty air removed from space. As
compared to an Air Handling Unit without Heat Recovery, an AHU equipped with Heat recovery at suitable condition has smaller

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BLUE STAR AIR HANDLING UNIT

exchanger in the AHU and hence lower Capacity Chiller/Condensing unit/Boiler, means lower power consumption. Blue Star FAHUs
can be supplied with following Air to Air Heat Recovery sections/combinations.

1. Double Wheel Energy Recovery – Total Energy and Sensible Energy Wheels.
2. Total Energy Wheel with or without Horse Shoe Heat Pipe.
3. Fixed Plate Heat Exchanger with or without Horse Shoe Heat Pipe.
4. Heat Pipe for Heat Recovery with or without Horse Shoe Heat Pipe.
5. Run Around Coil.

Rotating Heat Recovery Wheels (HRW)

Double Wheel Energy Recovery – with a Total Heat Recovery Wheel and a Sensible Heat Recovery Wheel: This system has two
energy transfer stages between adjacent fresh air and extract/exhaust air, with air flowing at opposite directions, creating a counterflow
heat exchange arrangement. In the first recovery phase, total energy exchange combining both latent and sensible energy transfer is
achieved by virtue of revolving Enthalpy Wheel having an Aluminum backbone structure with a desiccant coating and a large internal
surface area to transfer moisture and heat between the two airstreams having different temperatures and vapor pressures as the
driving force for energy transfer. During the cooling season, this wheel precools and dehumidifies the fresh air prior to entering the
main cooling coil, reducing the cooling coil load. Cooling coil dehumidifies the air to a certain dew point. Leaving the Cooling coil, this
dehumidified fresh air enters the second Sensible-only wheel where it absorbs heat from the extract/exhaust air stream and is reheated
to a specified neutral dry bulb. During this, by releasing heat to the supply airstream, exhaust air is pre cooled prior to entering the first
Enthalpy wheel, which further enhances cooling the fresh airstream.

Total Energy Recovery Wheel only: In this system, process is same as first recovery phase of the Double Wheel system, an Enthalpy
Wheel is equipped to precool and dehumidify the air entering the conventional fresh air handling unit. Again, the cooling coil
dehumidifies the air to a certain dew point, without reheating it to a neutral dry bulb temperature.

Blue Star supplies Eurovent Certified HRWs which are available in wide range of diameters from 500 mm to 2800 mm. These wheels
are available in two series – MS 200 and MS 270. Both series have a selectivity of 3A˚ molecular sieve desiccant coated Aluminum
substrate and this result in high latent recovery and control on cross contamination. Aluminum substrate eliminates any fire risks and
result in high sensible recovery and high structural strength. Purge section provides strict separation of airstreams preventing carryover
of bacteria, dust and pollutants from exhaust air to supply air. Purge section and sealing system limit cross contamination to 0.04% of
the exhaust air concentration by volume. Effective non-contact labyrinth seal ensures no wear and tear and long life. Wheel edges are
hardened as standard to suit marine and coastal application needs. Sectioned wheels capable of being assembled in the field are
available as options for above 2000 mm dia. Control Packages can be given as option.

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BLUE STAR AIR HANDLING UNIT

Fixed Plate Heat Exchanger (PHE)

Designed with air-to-air crossflow to transfer sensible heat. PHE consists of layers of plates which separates Supply and Exhaust
airstreams. These plates are constructed of high quality, aircraft-grade Aluminum, automatically machine formed for quality and
consistency. As an option, plates can be coated with Epoxy for additional corrosion resistance or constructed of Stainless Steel for
pressure resistance. Plate edges are folded to positively seal all edges from air leakage and crimped to ensure plate stability &
alignment and provided leading edge turbulence to enhance heat transfer. Plate spacing can be selected from very close to very open
to match the required efficiency and air flow requirements and are ensured complete separation of airstreams with no cross
contamination. PHE are washable using water and detergent. The housing is constructed of Galvanized Steel as standard; coating can
be given as optional.

Heat Pipes
Heat pipes are one of the most effective passive method of transferring heat across small temperature gradients. A sealed Copper tube
is evacuated and charged with a refrigerant which will absorb the heat from warm air stream (Evaporator section of Heat Pipe) and get
boiled. Due to its elevated vapor pressure, the vapor moves rapidly to the cooler Condenser section of Heat pipe, carrying with it the
absorbed heat. As the vapor reaches the condensing area of the heat pipe, heat is released to the cooler air and vapor condenses. The
liquid returns by gravity to complete the cycle.

Heat Pipes for Energy Recovery (HR HP) will be of the straight type and included within the AHU. Heat pipes are suitable for
Horizontal (side by side) and Vertical installations within the AHU, as per requirement. Heat pipe will straddle the airways in the supply
and extract decks of the AHU and will incorporate a dividing plate to separate the two airstreams. The two airways can be adjacent to
one another with minimum separation. The heat pipes will comprise a supply fin block directly coupled to an extract fin block and the
two airstreams are arranged to be in counter flow as they pass through the heat pipe.

Heat Pipes for enhanced Dehumidification are of “wrap-around” (HSHP – Horse Shoe) type included in the AHU around the main
Cooling coil. Heat pipe consists of a Pre-cool fin block upstream of the cooling coil linked to a Reheat fin block downstream of the
cooling coil by means of wrap-around pipes.

Casing of our Heat pipes are constructed of Galvanized Sheet Steel with a minimum thickness of 1.2 mm. Tubes are made of
refrigeration standard Seamless Copper C106 for heat exchanger use. Tube diameter will be minimum of 12 mm with grooved inner
surface to enhance the internal surface area and prevent pooling of liquid. External fins are of Aluminum with a minimum thickness of
0.11 mm. Fins are of the continuous plate type to maximize the external surface area rather than individually finned tube pattern. Fins
are wither rippled or louvered type to suit the application and spaced at such a distance as required by the condition specified. Copper
fins, vinyl pre-coated Aluminum or Blygold/Heresite post coated aluminum etc. are optional.

Run Around Coil

In this recovery system,the heat carried by one airflow is transferred to the other airflow indirectly, via a liquid medium. The heat
transfer fluid is a water/glycol mixture (brine) in the pump circuit. Supply air and extract air heat exchangers can be arranged at entirely
separate locations. They are merely connected by a hydraulic connection. As a result, they are suitable for applications in which no

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leakages between the supply and extract air are desired or permitted for hygienic reasons: for example, in hospitals as well as in the
food and pharmaceutical industries.

SELECTION TOOL
Blue Star DSA air handling unit Selection Program named BluestarAHU is tested and certified by EUROVENT.
- Customers can choose various construction/manufacturing options viz. sheet thickness, insulating material, fin material,
manifold material etc.
- Customer can design unit sections based on required application viz. mixing sections, filtration level, recovery section,
cooling/heating section, fan assembly sections, etc.
- It actually let customers to decide sectional possibilities in order to decide the dimensions of space required to place the unit.
- Divide the equipment in to modules in accordance with Project requirements.
- Obtain all technical information for the equipment selected, including the curves for the selected fan and its operating points.
- Estimate the cost of the selected equipment.
- Selection software is user friendly and highly intuitive.

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Blue Star has a policy of continuous product & product data improvement and reserves the right to change design & specifications without notice

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