Double Skin Air Handling UnitsWith Screwless Cabinets

Engineered to Deliver High Indoor Air Qualitydoor Air Quality

Blue Star has over six decades of experience in offering Expert cooling solutions for a wide

range of corporate and commercial applications. With this expertise and following the

success of standard series of screwless air handling units, Blue Star introduces Engineered

Double Skin Air Handling Units in screwless construction. These units are designed to offer

customised solutions to suit individual requirements.

The units are reliable, long-lasting and assure high indoor air quality. Features such as

screwless and sturdy construction, low noise and compact size make these units an ideal

choice for a large number of applications.

Double Skin Air Handling Units from the Experts

Flexible Canvas Connection

Base Frame

DIDW CentrifugalForward Curved Fan Copper Tubes

Ultraviolet Light

Pre Filter

AluminiumAnodized Frame

Bag Filter

Pre Filter

Sandtrap

Louvers

AA

Anti-CorrosiveHydrophilicCoated Fins

Enhancing Indoor Air QualityBlue Star has incorporated several advanced features in these air handling units. These

features are optional and contribute to a great extent in enhancing the indoor air quality.

Screwless Construction: Screwless design allows easy inspection, cleaning and

maintenance of the smooth inner surface, thereby reducing the risk of dirt and bacteria

accumulation. Moreover, there is no erosion of internal insulation material that

contaminates the air stream.

The panel frame arrangement has been improved by overlapping the wedge and the

special gasket. This arrangement, along with the modified filter frame design minimises

the chance of air leakage. It also makes the air handling units ideal for clean room and

pharmaceutical applications.

Internal sheet metal, filter and coil frame can also be offered in optional Stainless Steel

construction for these applications.

Efficient Filters: Apart from standard EU-3 type pre-filter, various types of filters such as

bag and fine HEPA Filters with different levels of filtration can be selected. These filters are

of progressive density type with high dust holding capacity and with lesser pressure drop,

ensuring high energy efficiency.

UVC Emitters: The option of UVC Emitters inside the units is available to combat the

growth of microorganisms. UVC Emitters ensure clean and sterile air at all times.

Moreover, the system functions efficiently, resulting in optimum power consumption.

Low Leak Dampers: Powder-coated galvanized or aluminium volume control dampers of

opposed blades and in aerofoil design are provided to maintain the fresh-air to return-air

ratio. A wide range of control options are available that include motorised and manual

operation of the damper. The option of sandtrap louvers is also available for outdoor

applications preventing sand or dust particles from entering the air handling unit.

Horizontal DSAHU Ceiling Suspended DSAHU Vertical DSAHU

Maximising Energy EfficiencyWith rising costs of electricity, it has become imperative to opt for additional

components which keep operation costs under control. The following components

also qualify the AHUs for green building applications:

Heat Recovery Wheels: Current energy performance guidelines emphasise the

usage of heat recovery wheels. These units utilise the energy from stale air to

pre-cool the air entering the AHU. Heat recovery wheels used in air handling units

recover up to 80% energy, thereby substantially reducing the operating costs.

Heat Pipes: Heat pipes are used to transfer the available heat thereby reducing

energy consumption and moisture content. Wrap-around heat pipes are used for

pre-cooling and reheating the air, whereas heat recovery heat pipes are used for

recovering the energy from exhaust air.

Variable Frequency Drives: Blue Star offers Variable Frequency Drives specially

customised for HVAC applications. These drives offer advanced variable speed

technology which helps reduce energy consumption substantially. In new

installations, a payback time of less than a year can be achieved when compared to

constant volume systems.

Energy Efficient Motors: Motors account for nearly two thirds of the power

consumption in an HVAC application. Even the smallest improvement in motor

efficiency can significantly reduce energy consumption. Blue Star offers EEF1

motors meant for continuous operation. These motors make the AHUs highly

energy efficient.

Energy Efficient Blowers: Energy efficient DIDW blowers have been incorporated.

These are available in three types: centrifugal forward curved, backward curved or

backward with aerofoil design.

The option of plug fan without the belt and pulleys makes it suitable for clean room

and pharmaceutical applications.

A Wide Range of Air Handling Units to Choose FromBlue Star offers a wide range of AHUs to suit individual requirements.

Standard Air Handling Units

Ceiling suspended ranging from 1670 to 13500 CMH (available in 3 direct-driven and 15 belt-driven models)

Vertical floor mounted ranging from 3500 to 25000 CMH (available in 10 models)

Horizontal floor mounted ranging from 3500 to 60000 CMH (available in 37 models)

Engineered Air Handling Units

Available from 3500 to 60000 CMH

Optimum SelectionBlue Star has designed its own AHU selection software which is used by field engineers

and is integrated in the manufacturing process. This helps in addressing customer

requirements effectively.

Standard Superior Features of the UnitCasing

The AHU is constructed on a thick fabricated GSS channel

Fan and motor is mounted on a fabricated slide rail. A specially designed motor

mounting base plate allows adjustment of the belt tension without disturbing

motor alignment. Flexible fire retardant canvas connection is provided at the

fan outlet.

The coil is placed on sliding channels for ease of service and maintenance

The drain pan is made up of Stainless Steel and insulated with a closed cell

elastomeric insulation to avoid surface condensation

Hinges and Handles

The fan section is provided with an access door for ease of serviceability of the

fan and motor

User-friendly nylon handles can be operated from both inside and outside

the casing

View Port and Marine Lamp

View port is provided on the fan door panel to enable monitoring the fan and

motor status

Marine lamp provides easy visibility

Fans

Centrifugal fans are of double inlet, double width type with forward curved

impeller. Fans are AMCA certified for sound and air performance, and are

statically and dynamically balanced. The whole fan assembly is trim balanced to

match ISO 1940 & AMCA 204.G 2.5 standards. The motor is of TEFC squirrel cage

induction type with IP55 protection and Class ’F’ insulation.

Limit Switch

Door limit switch automatically trips the motor/fan when the door is opened.

Double SkinAir Handling Units

For assured Indoor Air Quality.

For more information, please contact BLUE STAR LIMITED, International Division, Band Box House, 4th Floor, Dr. Annie Besant Road, Worli, Mumbai - 400 030. India. Tel: 91-22-66544000. Fax: 91-22-66544001. Visit us at: www.bluestarindia.com or email: exports@bluestarindia.com

INTL

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12 1

Blue Star is India’s leading

airconditioning Company, with over 6 decades

o f expe r i ence i n p rov id ing expe r t coo l i ng

solutions. On offer are Double Skin Air Handling

Uni ts that a re deve loped and powered wi th

innovative technology to provide end customers

w i t h e x c e l l e n t a n d o p t i m i z e d s o l u t i o n s .

Following are some of the options that you can

choose from:

•Horizontal Floor Mounted

•Vertical Floor Mounted

•Ceiling Suspended

Certificates

Flexible Canvas Connection

Base Frame

DIDW Centrifugal

Forward Curved Fan

Cu Tubes

Ultraviolet Light

Bag Filter

Anti-Corrosive

Hydrophilic

Coated Fins Pre Filter

Sandtrap

Louvers

AluminiumAnodized Frame

2 3

The panel is made of “Sandwich” construction

o f 25 mm or 46 mm, in jec ted w i th CFC f ree ,

R141b blended, polyurethane foam insulation

h a v i n g d e n s i t y o f 4 0 K g / m ³ a n d t h e r m a l

conduct iv i ty o f 0 .022 W/m K . Th is prov ides

e x c e l l e n t t h e r m a l i n s u l a t i o n a n d s o u n d

attenuation properties.

T h e c a s i n g p a n e l s ( I n n e r a n d O u t e r ) a r e

constructed of zinc coated steel sheets. Options

available on sheet specifications are:

• 0.6/0.8/1.0/1.2 mm steel sheet coated with

2 2 0 g / m ² g a l v a n i z e d z i n c ( Z n ) a n d 3 %

chromate.

• 0.6/0.8/1.0/1.2 mm steel sheet coated with

1 2 0 g / m ² g a l v a n i z e d z i n c ( Z n ) a n d p u r e

polyester pre-painted of coating thickness 25

µm for corrosion protection.

• 0.8/1.0/1.2 mm aluminium sheet.

• 0 .6/0 .8 mm sta in less s tee l sheet o f grade

SS-304/SS-316.

The panels are removable and are f ixed to the

frame with self-tapping screws. Labyrinth type

g a s k e t s e a l i n g b e t w e e n f r a m e a n d p a n e l

eliminates possibility of any air leakage.

The ent i re uni t is supported on ful l per imeter

b a s e f r a m e c o n s t r u c t e d f r o m h e a v y d u t y

galvanized steel sheet.

Product SpecificationsQuality Assurance

AHUs comply wi th the standards ment ioned

below:

• I S O 9 0 0 1 - 2 0 0 0 o n Q u a l i t y M a n a g e m e n t

System.

• E N 1 8 8 6 , E N 1 3 0 5 3 o n M e c h a n i c a l a n d

Performance characteristics.

i. Casing Strength: Class 2A

ii. Casing Air Leakage: Class A

iii. Thermal Transmittance: Class T2

iv. Thermal Bridging Factor: Class TB2

• AMCA 210 on Fans Air Flow performance and

AMCA 300 Sound performance

CasingRigid frame work construction made of extruded

hol low aluminium anodized prof i le with nylon

f i b e r g l a s s c o r n e r j o i n t s a n d r e i n f o r c e d

internally.

Optional thermal bridge frame work for fresh air

appl icat ion and outdoor instal lat ion ensures

el iminat ion of condensat ion phenomenon on

frame work.

Coils

Primarily coils are designed for chilled water and

direct expansion applications, manufactured

from ½” OD copper tubes of staggered

configuration and counter flow design.

The Free Flow Fins configuration combines a

mild ripple with die formed directional guide

channels. These create a turbulent wiping action

in the normally dead area behind the tubes. And

thereby prolong the contact with cooling surface.

Such advance engineering techniques allow

AHUs to improve the heat transfer capability and

ensure the optimum balance between a high

heat transfer coefficient and a minimum

pressure drop.

Various circuiting methods provide more

flexibility, wider selection, and unexcelled

performance optimization.

Mechanical expansion of tubes

assure tight bonding between

tubes and fins for better heat

transfer.

The full channel galvanized

steel frame and intermediate support provides

rigid frame structure.

The headers are heavy section with seamless

copper tubing. The end connection is made in

steel pipe for a welded joint. One drain and one

vent fitting are conveniently located on inlet and

outlet connection.

Complete coils are factory pressure tested at

325 psig compressed air under water. Coils are

designed for operation up to 250 psig design

working pressure at 300°F.

Drain PanDrain pan with wider width and differential slope

ensures comple te d ra inage o f condensate .

Typically the drain pan is fabricated from 0.8 mm

th ick s ta in less s tee l g rade

SS -304 insu la ted w i th 10 .0

mm close cel l , cross l inked,

irradiated, fire retardant grade

p o l y e t h y l e n e m a t e r i a l .

Intermediate tray is provided

for stacked coils to collect the

condensate from the top coil.

Coils with hydrophilic coating are available as an

option. Pre-coated fins have distinct advantage

ove r conven t iona l f i ns because o f i t s wa te r

shedding propert ies, corrosion resistance and

exce l l en t UV res i s tance . These p rope r t i es

increase coi l e f f ic iency and enhance cool ing

capacity.

For c lear room app l ica t ion , the opt iona l fu l l

channel frame constructed of stainless steel SS

304 grade is available.

4 5

Filters The filter comprises of high quality synthetic filter

media from FilterAir. The media is thermally

bonded with progressive

density to have high dust

holding capacity and low

initial pressure drop. The

media is certified as self

extinguishing class 2 as per UL 900. The filters’

efficiency is tested in accordance with ASHRAE

52.2-1999 standards. Filter media is stamped

with filter class as a proof of originality.

• Pre-Filters

The media in pleated

construction is housed in

g a l v a n i z e d / a l u m i n i u m

cassette type frame

supported with aluminium

mesh on air leaving side.

Filters efficiency conforms to G3 grade, 90%

down to 10 micron as per EN-779 standard.

• Preliminary Bag Filters

The pockets are housed

in galvanized/aluminium

flange type frame. These

pockets are welded at

edges into a rigid and

aerodynamic shape to

reduce the pressure drop. Special welded

spacers ensure full media utilization. Filters’

efficiency conforms to F5 grade, 99% down to

5 micron as per EN-779 standard.

• Secondary Bag Filters

The synthetic media consists of strategically

layered and blended melt-blown polypropylene

fibers fastened to a non-shed, high density

polypropylene backing. Vertical separators are

incorporated into each pocket to effectively

channel air throughout the media to prevent

excessive turbulence and maintaining low

pressure drop.

F7 & F9 Filters efficiency conforms to 98% down

to 3 micron and 99.9% down to 3 micron

respectively as per EN-779 standard.

• HEPA Filters

Ideal design to be used in hospitals,

pharmaceutical, electronics

and clean room applications.

The filter features high

efficiency micro-glass paper

pleated to form compact

media pack. Filters are scanned for leak-free

construction.

The filter utilizes a continuous sheet of wet-laid

micro-fiber media that is deep pleated and can

operate in applications with 100% humidity.

Super Flow, H13 Filters efficiency conforms to

99.997% down to 0.3 micron particle size at

rated flow as per EN 1822 standard.

FansFans used are Kruger make, AMCA cert i f ied,

energy efficient.

Al l wheels are stat ical ly, dynamical ly and tr im

balanced to ISO 1940 and AMCA 204/3 – G2.5

standard. The operating limit of each fan type is

designed to meet the requirement of class I, I I

a n d I I I l i m i t a s d e f i n e d i n A M C A s t a n d a r d

99-2408-69.

Bearings used are either

deep groove ball bearing

t y p e w i t h a n a d a p t o r

sleeve, or spherical roller

b e a r i n g t y p e a t b o t h

s ides fo r d i f fe rent duty

appl icat ions. Housings are fabr icated f rom

ga lvan ized shee t s tee l and sha f t f rom C45

carbon steel.

Various options available on types of fans used

in the air handling unit are:

• DIDW, Centr i fugal Fan wi th Forward Curve

Wheel.

• DIDW, Centr i fugal Fan with Backward Curve

Wheel.

• DIDW, Centr i fugal Fan with Backward Curve

Air Foil Wheel.

• P lenum (P lug ) Fan w i th Backward Curve

Wheel.

Motor and Drive Package M o t o r s u s e d a r e e n e r g y e f f i c i e n t , t o t a l l y

enclosed fan cooled (TEFC) type, wi th IP 55

protect ion, Class F insulat ion, three phase,

50 Hz, 415 V, Squirrel cage induction motor.

Dual duty, Taper lock, Spl i t bush, are used to

el iminate the re-boring and keyway problems

and convenience in maintenance. Matching

We d g e “ V ” b e l t s a r e u s e d f o r h i g h p o w e r

transmission.

Var ious opt ions are made

a v a i l a b l e t o m e e t t h e

s p e c i f i c , c u s t o m i z e d

requirements:

• Dual Speed

• Flame Proof Construction

• Variable Pitch Pulley

The complete fan and motor assembly is placed

on separate aluminium extruded base frame,

isolated from the main unit with rubber mounts /

spring isolators.

Fire retardant, Flexible connectors are provided

between the fan discharge and main casing.

6 7

Variable Frequency Drive Fully dedicated to HVAC applications, advanced

variable speed technology is used to bring down

energy and maintenance cost. Drive includes an

RFI filter, DC link coils and an in-built 2 – zone

PID controller.

The detachable Local Control

Panel makes it easy to copy

programming instructions. It

has several read outs to

choose from with crystal sharp

display. It also has a true

Hand-Off-Auto function with

local and remote control. In new installation, a

payback time of less than one year can be

achieved when compared to constant volume

systems.

Intelligent ControllerThe Intelligent controller is a highly advanced,

user friendly controller with a micro processor

based program which comes

with an in-built display.

The Blue Star solutions for Air

Handling Unit market completes the range by

offering all the components like electrical panel,

pressure, temperature, humidity, air quality

probes, differential pressure switch, flow switch,

actuators, etc required for the control system

and application to meet varied customer

requirements.

A total of 24 different pre-configured systems are

available and can be selected by setting just one

parameter.

Heat Recovery Wheel Current ASHRAE standard 62-2001 recommends

the 20 ~ 30 CFM per person in a conditioned

room to avoid Sick Building Syndrome and

maintain the High Indoor Air Quality.

Stale air from the airconditioned space is

exhausted through one half of the heat wheel

while fresh air is drawn through the other half of

the wheel in a counter flow pattern thereby

achieving energy recovery. Also managing

savings in operation cost.

Heat recovery wheels use custom made metallic

honey comb matrix coated with Molecular Sieve

dessicant.

The heat recovery wheels used

are suitable at 80% equal and

both Sensible and Latent heat

recovery at 700 FPM face air

velocity.

The rotary heat exchangers are provided with

purge section to reduce the penetration of

exhaust air to supply air. Non contact labyrinth

seals are placed on the rotors perimeter and

dividing line to provide additional protection

against air leakages.

Heat wheels used are certified under ARI 1060

certification program.

VFDDampers T h e v o l u m e c o n t r o l d a m p e r s h a v e b e e n

designed to provide positive control of air within

the airconditioning system.

Dampers are constructed

from high quality aerofoil

d e s i g n a l u m i n i u m /

galvanized extrusion and

s u i t a b l e f o r f l a n g e d

connection within square

or rectangular shape.

Blades are mainly pivoted on PVC bushes and

operate through PVC gear system which is fully

enclosed with the damper frame.

A wide range of control opt ions are avai lable

and include motorized and manual operation

Electric Heater

“U” shaped tubular finned heaters are used to

increase surface area for effective

heat ing. These heaters come with

mounting clamp and insulated with

heat shrinkable sleeve for electrical

connections. Watt density of heaters

is maintained at 5 watts / cm².

Following are the various parameters which can

be controlled efficiently:

• Outside air & air mixture damper, with free

cooling, free heating and enthalpy control

• Intake & supply fan, with two steps or inverter

control

• Water heating coil and

electric heaters, with pre-

heating management

• Water cooling coil

• Direct expansion with condenser control

• Direct expansion with three On/Off steps

• Cross-flow, rotary and double coil heat

recovery unit

• Supply & return air filter

• Adiabatic/Steam humidification with On/Off or

modulating control

• Built-in daily/weekly timer

• All models are network connection enabled,

using RS 485 port & MODBUS protocol

8 9

Width Height Width Height Air Quantity AHU Model @ 2.54 m/s AHU Dimensions with 25 AHU Dimensions with 46 Section Length Filter Area Section Length Coil Area Section Length Fan Dia. mm thk. PUF Panels mm thk. PUF Panels

CMH mm mm mm mm mm mm mm Sq. mtr. mm mm mm mm mm mm Sq. mtr. mm mm mm mm mm mm mm mm mm mm

E - 035 3453 997 657 1030 690 458 458 938 0.40 35 458 875 875 1153 1153 0.377 557 696 835 974 319 319 597 418 1014 250

E - 050 4870 1099 796 1132 829 458 458 938 0.54 35 458 875 875 1153 1153 0.532 557 696 835 974 319 319 597 418 1153 280

E - 080 7969 1251 1074 1284 1107 458 458 1216 0.90 35 458 875 875 1153 1153 0.871 557 696 835 974 319 319 597 418 1292 355

E - 120 12396 1810 1074 1843 1107 597 597 1216 1.44 35 458 875 875 1153 1153 1.335 557 696 835 974 319 319 597 418 1153 450

E - 160 15554 1949 1213 1982 1246 597 597 1500 1.70 35 458 875 875 1153 1153 1.700 557 696 835 974 319 319 597 557 1292 500

E - 200 20069 2088 1373 2121 1406 875 875 1500 2.16 35 458 875 875 1153 1153 2.194 696 835 835 974 319 319 597 557 1431 560

E - 250 25323 2366 1500 2399 1533 875 875 1900 2.73 35 458 875 875 1153 1153 2.768 696 835 835 974 319 319 597 557 1431 630

E - 300 30458 2546 1627 2579 1660 875 875 1900 3.36 35 458 875 875 1153 1153 3.329 696 835 835 974 319 319 597 557 1570 710

E - 400 39372 2685 1996 2718 2029 1014 1014 2300 4.50 35 458 875 875 1153 1153 4.303 557 696 835 974 319 319 597 696 1889 800

E - 500 49672 2963 2250 2996 2283 1153 1153 2900 5.40 35 458 875 875 1153 1153 5.429 557 696 835 974 319 319 597 835 2167 900

E - 600 60563 3241 2440 3274 2473 1153 1153 2900 6.60 35 458 875 875 1153 1153 6.619 557 696 835 974 319 319 597 835 2306 1000

Notes:

1. AHU with single Modular unit.

2. Please add 100 mm of extrusion length in each module.

3. Add 100 mm in the AHU height for Base channel.

4. Standard empty sections are available in sizes : 180, 319, 458, 597, 736, 875, 1014 & 1153 mm.

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Technical Specifications

* Specifications are subject to change due to continuous product development.

10 11

Length Width Height 12mm ESP 20mm ESP With 4-row Coil With 6-row Coil

mm mm mm sq. m. CFM CFM KW KW Kg Kg

DVW-035 785 1040 1321 0.387 2083 3542 0.75 1.1 190 205

DVW-050 835 1396 1387 0.568 3056 5194 1.1 1.5 225 245

DVW-070 885 1599 1532 0.755 4063 6906 1.5 2.2 330 360

DVW-100 1035 1776 1861 1.123 6042 10271 2.2 3.7 395 435

DVW-140 885 2233 1904 1.471 7917 13458 3.7 3.7 470 520

DVW-170 1035 2741 2021 1.858 10000 17000 3.7 5.5 560 610

DVW-200 1035 2945 2059 2.181 11736 19951 5.5 5.5 590 650

DVW-250 1085 2945 2288 2.684 14444 24556 5.5 7.5 670 745