Bespoke Boxer: Air Handling Units Installation Manual

BESPOKE BOXER
Air Handling Units

Installation Manual
1.0 SAFETY INFORMATION
• The provision of the electrical supply and the connection of the unit to the electrical supply must
be carried out by a qualified electrician.
• This unit must be earthed.
• All-pole disconnection from the mains as shown in the wiring diagram must be incorporated
within the fixed wiring and shall have a minimum contact separation of 3mm in accordance with
latest edition of the wiring regulations.
• Isolate from power supply before removing any covers. During installation / maintenance ensure
all covers are fitted before switching on the mains supply.
• Ducting must be securely fixed with screws to the spigot to prevent access to live parts. Duct
runs terminating close to the fan must be adequately protected by suitable guards.
• Sharp edges need to be handled with caution; most of the air handling equipment will contain
sharp edges on the internal and external surfaces. Care should be taken to ensure that all
personnel are aware of this and precautions are implemented to ensure no wounding is caused.
• This appliance should not be used by children or persons with reduced physical, sensory or
mental capabilities or lack of experience and knowledge, unless they have been given supervision
or instruction concerning the safe use of the appliance by a person responsible for their safety.
Children shall not play with the appliance. Cleaning and user maintenance shall not be carried
out by children.
1.1 Symbols
GENERAL WARNING
Signifies a general warning regarding hazard specified by supplementary information.
ELECTRIC SHOCK
This unit must be completely electrically isolated before any panels are removed. Check
mains supply and control connections.
ROTATING PARTS
This unit contains fast moving rotational parts which may start automatically. It is the
sole responsibility of the installer to adequately guard these components.
REFER TO INSTRUCTION MANUAL
Read and understand the installation and maintenance manual before installing,
operating or maintaining this product.
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk 09. 07. 21. Document Number 671506
1
Installation Manual BESPOKE BOXER
1.2 Important Information The Plant is fully isolated from the mains supply and allowed to run
down for a minimum of five to ten minutes before opening any access
This manual contains important information on the safe and door prior to the commencement of any maintenance work.
appropriate assembly, transport, commissioning, operation,
maintenance, disassembly and simple troubleshooting of the product. When maintenance work is finished, please ensure that the unit is left
in a clean state, and all access doors /panels are fastened and locked
While the product has been manufactured according to the accepted correctly (locked handle returned to holder).
rules of current technology, there is still a danger of personal injury or
damage to equipment if the following general safety instructions and At no point should a unit be used for the storage of tools or working
the warnings contained in these instructions are not complied with. equipment.
•Read these instructions completely and thoroughly before 2.0 INTRODUCTION
working with the product.
The information contained in this document provides details of
•Keep these instructions in a location where they are accessible installation, operation and maintenance for installers and users of the
to all users at all times. BESPOKE BOXER Air Handling Units.
•Always include the operating instructions when you pass the The BESPOKE BOXER range of units are manufactured from Magnelis
product on to third parties. corrosion resistant steel, with either 30 or 50mm double skinned panels
1.3 Personal Protective Equipment and anodized aluminium frame; Mechanical strength, D1; Leakage class,
L2; Thermal transmittance, T4; Thermal bridging, TB4.
The following minimum Personal Protective Equipment (PPE) is
recommended when interacting with Nuaire product: The range has high efficiency centrifugal fans and where applicable,
high efficiency thermal wheel, plate heat exchanger or run-around
•Protective Steel Toed Shoes - when handling heavy objects. coils. A G4 pre-filter and F7 main filter on supply as standard with M5
•Full Finger Gloves (Marigold PU800 or equivalent) - when filtration of the extract air. BPS range includes optional heating (LPHW,
handling sheet metal components. Electric or Gas Fired) and cooling (Chilled water, DX).
•Semi Fingerless Gloves (Marigold PU3000 3DO or equivalent) A wide selection of ancillaries are available, including attenuators,
- when conducting light work on the unit requiring tactile dampers, frost coils, recirculation modules and weather terminals.
dexterity. BESPOKE BOXER units are delivered to site control free as standard,
•Safety Glasses - when conducting any cleaning/cutting operation allowing them to be integrated with control systems supplied by
or exchanging filters. others.
•Reusable Half Mask Respirators - when replacing filters which General information regarding performance and specification for the
have been in contact with normal room or environmental air. equipment can be obtained from our technical literature, and/or project
specific documentation.
Nuaire would always recommend a site specific risk assessment by a
competent person to determine if any additional PPE is required. 2.1 Receipt Of Equipment
1.4 Activity Guidelines To ensure that the delivery vehicle is loaded according to the
planned method of offloading, Nuaire should be notified at order
Component parts are usually not fitted with safety guards i.e. stage to ensure coordination.
fan inlet. The casing of the unit acts as a protective guard for all
component parts. Where possible, double deck sections leave Nuaire fully assembled.
For more information on unit delivery please contact our
Please ensure that prior to commencing any activity, the following commercial orders team on 02920 858 200.
guide lines are adhered to:
All equipment is inspected prior to despatch and leaves the factory in
Installation must be completed by competent persons, in accordance good condition. Upon receipt of the equipment an inspection should be
with good industry practice and should conform to all governing and made and any damage indicated on the delivery note.
statutory bodies i.e. IEE, CIBSE, etc.
Particulars of damage and/or incomplete delivery should be endorsed
During installation, commissioning, operation and maintenance of by the driver delivering the goods before offloading by the purchaser.
an air handling unit, operatives may be exposed to hazards including,
rotating components, refrigerants and high voltage electricity. If No responsibility will be accepted for damage sustained during the
misused or handled improperly, each of these items has the potential to offloading from the vehicle or on the site thereafter.
cause bodily injury or death. All claims for damage and/or incomplete delivery must be reported to
Identification and recognition of inherent hazards is the obligation of Nuaire within two days of receipt of the equipment.
responsible personnel. They must protect themselves and others by
proceeding with care and consideration to health and safety measures.
All risk assessments have been carried out and are in place prior to
carrying out any activity.
The relevant protective equipment and attire is worn by each relevant
member of staff.
That the unit Nuaire have supplied meets the standards written in the
technical specification.
The necessary lifting gear and site plant is available to lift and position
the unit in accordance to the technical drawings.
2
2.2 Handling Of Equipment 2 Typical Base Frame Detail
The images in Figure 1 show examples of typical lifting methods.
Actual lifting plan and risks must be assessed by competent
personnel before moving the unit.
When offloading, care must be taken to ensure that the AHU is
kept level at all times.
To ensure that no roof damage occurs additional timber packaging
must be used. CENTRE SUPPORT CAN BE ON EITHER SIDE OF CENTRE LINE
Section Section Section
The weight of the unit modules and palletised items are displayed on length length length
the packaging.
50.0
100.0
Some of the modules have an uneven weight distribution, and this will 50.0
be indicated by labelling where appropriate.
100.0
Section width
50.0
Offloading and positioning of the equipment is the responsibility of
the purchaser. Items should only be lifted by competent personnel 100.0
50.0
following appropriate risk assessment.
50.0
Spreaders should be used when lifting with slings to avoid damage 76, 100, 150 or 200
to the casings. Care must be taken to ensure that slings are correctly A
A (1:5)
positioned to avoid crushing and twisting of the unit casings. Care
should be taken to ensure the units remain upright and level at all
Overall unit length
times. 50.0
50.0
Where channels and/or support frames are bolted to the underside of 50mm x 50mm Lifting hole
the unit casing, slings or fork-lift arms should be positioned in the base
frame lifting apertures, full details of which are in the following section. 2.4 Equipment Protection
If lifting lugs / eyes have been supplied / or fitted it is recommended Unless otherwise specified, unit sections will be delivered to site
that they are used. covered in “shrink wrap” polythene, which should provide a more
1 Lifting Methods than adequate level of protection against inclement weather. Should
alternative methods of unit protection be required (i.e. timber, Corex,
Palletised. Forklift. or flame retardant materials), Nuaire should be notified of the specific
requirements at the pre- contract stage. Waste must be disposed of by
a registered waste carrier in accordance to national regulations.
2.5 Equipment Storage
Units that are intended for external locations are generally not
fully weatherproofed until their installation, including ductwork
connections, is complete.
The equipment must be stored in a dry, internal location. Ductwork
connection apertures should be sealed against the ingress of dust,
water and vermin. Do not stack units, modules or components that are
not designed to be stacked.
Where fans are to be stored or bonded for extensive periods either in
warehouse, under site conditions or in the installed state, we make the
following additional recommendations:
•Motors should be stored at ambient temperatures between
-16°C and +40°C and at relative humidity (RH) below 90%RH.
•Fans should be retained in their original packaging and stored
Assembly with Slings via spreaders fitted to on level ground.
base frame. unit with base frame. •Fans should be protected from damage, excess moisture and
ingress of dirt, dust or other contaminants.
2.3 Base Frame Lifting Points
•Relax the belt tension on belt driven equipment.
When units are constructed of multiple modules each module will have
•Turn fan and motor shafts at three monthly intervals to
its own individual base frame, which is then connected to the next to
prevent the brinelling effect on the bearings. Brinelling is a
assemble the full system.
flattening or settlement of the shaft in the bearing housing.
All base frame sections will have 50mm square lifting holes at the
The conditions above will apply and any deviation from them could
end of each side to enable lifting. In addition to this, covered fork
nullify the warranty.
lifting channels are located across the width of the base frame, if the
module length is sufficient to allow this. For shorter modules the fork
lifting points will be along the length of the section, without a covered
channel (Figure 2).
3
3.0 MECHANICAL INSTALLATION 3 Joint Details
Fixing rod.
Installation must be carried out by competent personnel, in accordance
with good industry practice, with the appropriate authority and in
conformance with all statutory and governing regulations.
The unit should stand upright and level on the floor, foundation or
supporting steelwork which should be rigid, flat and level and should
be capable of supporting the weight of the unit including water or
refrigerant in the coils.
Nuaire takes no responsibility for the coordination of support.
3.1 Installation Location
To prevent possible reintroduction of contaminated air through the
outside air intake, the unit should be located away from building flue
stacks or exhaust ventilators.
Once assembled and in position, sufficient free space must be available Fixing rod / External clamp detail.
adjacent to the unit for future inspection, maintenance, component
service, repair and replacement and connection of services.
Connection plate
It is recommended that at least the unit width (vertically arranged Fixing rod
units); or half the overall unit width (horizontally arranged units) + Pentapost frame
100mm be allowed. For units with a horizontal layout, access is
Inner panel skin
typically required to both sides of the unit casing.
Panel infill
Sufficient clearance for U-traps on condensate drain and overflow
Outer panel skin
connections should also be considered by the purchaser.
3.2 Air Leakage
Loading, transportation, off loading and site positioning can cause
the air handling unit structures to move, therefore panel seals will not
always remain fully intact.
Optional external clamp
It is inevitable that in such cases, re-sealing of the units panels and
joints may have to be carried out on site for the air-handling units to Optional external clamp.
achieve the required leakage classification.
Door locking mechanisms may also have to be adjusted.
Nuaire cannot be held responsible for the units failing a site leakage
test if the above have not been carried out correctly.
3.3 Modular Unit Section Joints
All sections should be accurately aligned and adjoined prior to bolting
together using the fixings and gaskets provided by Nuaire.
Modular units are supplied with matching internal connection plates
with a single bolt hole provided to each corner through which the
sections are bolted together. Unit access panels must be removed to
perform the assembly operation. Plates will either have clearance holes,
or one face with a threaded insert and the other with a clearance hole. 3.4 Weather Resistant Units
In instances of restricted access to the internal corner bolts, external Weather resistant units in multiple sections will have sectional roof
clamps can be provided to facilitate external connection of modules. components that must be fitted and sealed after the unit sections
are bolted together. All necessary nuts, bolts, washers and sealant are
A sealing gasket should be applied as necessary to the mating faces of supplied with each unit and are normally bagged and located within the
the unit frames before bolting together. fan section. Suitable mastic sealant is to be provided by others.
Air leakage, air blow marks to the unit casings and unacceptable noise The equipment must not be exposed to the weather in an unassembled
levels could result if the correct installation procedures are not adhered or partially assembled state. All ductwork, sealing and assembly
to. work must be completed before the unit can be considered weather
resistant.
Where the weatherproof roof assembly of two sections meet, a
weatherproof cover strip must be applied to seal the seam, this will be
supplied with the unit.
4
4 Units With Weatherproof Roofs 3.6.4 Condensate Drains
Modules that incorporate heat recovery, cooling coils or humidifiers
may produce condensation during use. An insulated drip tray and drain
connection is provided, and should be connected to a suitable drainage
point.
Where plate heat exchangers are in use, condensate drainage points are
provided. It is the installers’ responsibility to ensure connection to the
appropriate trap and drainage. Due to the bespoke nature of these units
condensate connection locations can vary during the design process
and should be confirmed on an individual basis.
Horizontal plate heat exchangers have 2x 22mm drain connections.
Connections are typically located on the underside of the PHX module
Above Left: Horizontal unit with weather kit. at the extract inlet and extract outlet (Figure 5).
Vertical plate heat exchangers have 2x 22mm drain connections.
Above Right: Vertical (Stacked) unit with weather kit. Connections are typically located at the bottom of the access side of
the PHX module (Figure 6).
Below: Roof assembly detail.
Provision may be required, and if so, should be made, for the fitting of a
correctly sized cleanable trap to each drain connection.
5 Condensate Connections For Horizontal Units With PHX
Sidejjjj
View
3.5 Thermal Wheel Transport Packing

Thermal wheel modules can be delivered with transport packing blocks,
ensure any transport blocks are removed prior to operation of the 1x 22mm Condensate Connection
thermal wheel.
The thermal wheel belt is unhooked to prevent the thermal wheel belt
from stretching during transportation.
End View
The thermal wheel motor is attached via a hanging motor bracket. To
install the belt lift the spring motor upwards, hook the belt onto the
pulley and slowly release the motor.
Ensure that the rotation sensor is aligned with the sensing studs,
as this can become misaligned during transport/installation thus
causing a fault signal.
3.6 Connections 1x 22mm Condensate Connection
3.6.1 Ductwork 6 Condensate Connections For Vertical Units With PHX

Nuaire do not provide ductwork connections with units, instead Access Side View
the open ended framework should be utilised. Spigots are available
as an option; refer to technical documents for information relating
specifically to the manufactured unit.
3.6.2 Coils
When connecting coils, special care is needed to allow for expansion
and contractions. Prior to any equalising connection, ensure that the
thermostatic expansion valve for the DX coil is securely fitted.
Each coil section should be trapped and special care should be taken to
ensure that there are no vertical rising condense lines, unless pumped.
If a frost coil is not fitted then appropriate control methods must
be taken to prevent the coils, filters and other equipment from
freezing (by others).
3.6.3 Pipework
Care should be taken to ensure that all pipework is adequately
supported, therefore ensuring that no additional weight is added to the
unit. Extra precaution should be taken to prevent pipe damage on site, 2 x 22mm Condensate Connections
as the fragile pipework will protrude from the side of the unit.
5
Under Negative Pressure 3.8 Filters
If the condensate tray is located at the inlet side of the fan (i.e. under Filters will be provided in banks on suitable slide rails, so that they
negative pressure) then calculate the values of A & B as shown below can be withdrawn. Magnehelic gauges are offered as standard unless
(Figure 7). otherwise instructed.
10Pa = 1mm H2O 3.8.1 Spare Filters
A = Fan inlet pressure (mm H2O) +25mm (minimum). Allow 100mm If specified with order, spare sets of filters will be provided and should
for these units if pressure is unknown. be stored in a clean, dry environment. Should you require spare filter
B = A/2 (minimum). media, please contact Nuaire.
Under Positive Pressure 3.8.2 Panel & Bag Filters with Side Withdrawal
If the condensate tray is located at the outlet side of the fan (i.e. under Insert the filters by sliding them into the railing provided. If specified,
positive pressure) then calculate the values of A & B as shown below blanking filters are fitted at the end of the railing.
(Figure 7). 9 Side Withdrawal Filters
A = 25mm (minimum).
B = Fan outlet pressure (mm H2O) + 25mm (minimum).
Allow 100mm for these units if pressure is unknown.
7 Condensate Trap Dimensions
Hand tight plug
From
condensate
drain pan Hand tight plug
Connect to
A ventilated
downpipe
to drain
B Capping strip
3.8.3 Panel & Bag Filters with Front Withdrawal

3.7 Fan Transit Brackets (AC Motors) Insert filters squarely into the frames and retain using retaining P-clips.
Transit brackets are factory fitted to prevent the blowers moving during 10 Front Withdrawal Panel Filters
transport and must be removed to prevent excessive vibration during
operation. The specific location and number of transit brackets varies by
unit. Check the unit drawing for the location and number of blowers.
Before use ensure the transit brackets have been removed from each
blower within the unit (Figure 8).
•Loosen and remove the transit bracket bolt.
•Remove the transit bracket away from the anti-vibration mount.
Repeat for each bolt.
•Store the transit brackets and bolts in a safe location if required for
future use.
8 Fan Transit Brackets (AC Fans)
11 Front Withdrawal Bag Filters
Transit Transit Bracket

Bracket
Bolt
6
3.9 Control Dampers 4.1.2 EC Motor Fans
Care should be taken to ensure that all spring return actuators have 13 Typical Fan (EC Motor) Wiring
stopped running and completed their stroke. If not, the connection
needs to be loosened and the actuator should be left to drive until the
motor stops running.
When the unit is powered, dampers should be checked to ensure that
they operate freely and close tightly.
3.10 Final Inspection
•Thoroughly inspect the unit after installation is complete.
•The inside of the unit should be checked; any objects which may
have been left should be cleared.
•Check fan impellers, scrolls and outlets. No. Conn. Desig. Function / Assignment
•Remove any transit protection fittings that may be attached to the KL1 1 L1 Mains supply connection, supply voltage 3~380-480 VAC;
fan or motor base frame, and that all traps are primed. 50/60 Hz
•Close all access door seals for damage, and replace any panels that KL1 2 L2 Mains supply connection, supply voltage 3~380-480 VAC;
50/60 Hz
have been removed.
KL1 3 L3 Mains supply connection, supply voltage 3~380-480 VAC;
4.0 ELECTRICAL INSTALLATION 50/60 Hz
PE PE Earth connection, PE connection

The electrical wiring must be carried out by competent persons, in
accordance with good industry practice and should conform to all KL2 1 NO Status relay, floating status contact; normally open; close
governing and statutory bodies i.e. IEE, CIBSE etc. with error
KL2 2 COM Status relay; floating status contact; changeover contact;

Ensure suitable earth bonding is maintained on all AHU sections.
common connection; contact rating 250 VAC / max. 2 A
4.1 Wiring (If Applicable) (AC1) / min. 10 mA
KL2 3 NC Status relay, floating status contact; break with error

4.1.1 AC Motor Fans
KL3 1 RSA Bus connection RS-485, RSA, MODBUS RTU; SELV
Inverter speed control is required for these units and can be provided by
Nuaire as optional extras, any inverters should be configured to match KL3 2 RSB Bus connection RS-485, RSA, MODBUS RTU; SELV
the design and running frequency that is provided on the datasheet of KL3 3/10 GND Signal ground for control interface; SELV
each specific fan.
KL3 4 Ain1 U Analogue input 1, set value: 0-10 V, Ri = 100 kΩ,
Care should be taken to ensure that the rotation of three phase motors parametrisable curve, only usable as alternative to input
correspond with the direction shown on the frame. Ain1; SELV
KL3 5 + 10 V Fixed voltage output 10 VDC, +10 V ±3%, max. 10 mA,

All electrical connections to the fan are to be made using flexible cable
short-circuit-proof, power supply for external devices (e.g.
and containment materials to allow for the movement of anti-vibration potentiometer), SELV
mounts.
KL3 6 Ain1 I Analogue input 1, set value: 4-20 mA; Ri = 100 Ω,
12 Typical Fan (AC Motor) Wiring parametrisable curve, only usable as alternative to input Ain1
Key: U; SELV
KL3 7 Din1 Digital input 1: enabling of electronics, Enabling: open pin

Internal Factory Connection
Mandatory Customer Connection or applied voltage 5-50 VDC. Disabling: bridge to GND or
applied voltage <1 VDC. Reset function: triggers software
Inverter Drive reset after a level change to <1 VDC; SELV
INPUT OUTPUT
KL3 8 Din2 Digital input 2: parameter set switch 1/2, according to
U1 V1 W1 PE U2 V2 W2 EEPROM setting, the valid/used parameter set can be
selected via bus or via digital input DIN2. Parameter set
1: open pin or applied voltage 5-50 VDC. Parameter set 2:
Motor
bridge to GND or applied voltage <1 VDC; SELV
Terminal U1 V1 W1
L1 L2 L3
Connections KL3 9 Din3 Digital input 3: controller function of integrated controller,
V1
3 Phase only U1 W1 according to EEPROM setting, the controller function of the
Motor
Inverter Speed Control 3 Phase integrated controller is normally/inversely selectable per bus
or per digital input. Normal: open pin or applied voltage 5-50
VDC. Inverse: bridge to GND or applied voltage <1 VDC; SELV
400V 3 phase 50Hz supply KL3 11 Ain2 U Analogue input 2, actual value: 0-10 V, Ri = 100 kΩ,
Notes:
Inverters are typically unconfigured, and require configuring parametrisable curve, only usable as alternative to input
to suit project specific fans and control applictions. Ain2; SELV
KL3 12 + 20 V Fixed voltage output 20 VDC, +20 V +25/-10%, max. 50 mA,

short-circuit-proof, power supply for external devices (e.g.
sensors); SELV
KL3 13 Ain2 I Analogue input 2, actual value: 4-20 mA, Ri = 100 Ω,

parametrisable curve, only usable as alternative to input Ain2
U; SELV
KL3 14 Aout Analogue output 0-10 VDC, max. 5 mA, output of the current
motor level control coefficient / motor speed parametrisable
curve; SELV
7
4.1.3 BMS Differential Pressure Switch 16 Typical Electric Heater Wiring
An external power supply delivering 10-35 VDC with a minimum Key:
current capability of 40ma must be used to power the control loop in
Internal Factory Connection
which the PDGAUGE2/BMS is connected. TH
L3/LOAD3
Mandatory Customer Connection
LOAD1
LOAD2
1 2 3 4
L2
If the receiver requires a 1-5 volt input, insert a 250 ohm, 1/2 watt
L1
MANUAL RESET HEATER
resistor in series with the current loop but in parallel with the receiver OVER-HEAT
CUT-OUT
L1
input (Figure 14). RL becomes the 250 ohm resistor and point X and Y PUSH
TO RESET
L2
are connected to the receiver input, point X being positive (+) and point
L3
Y negative (–) or ground.
14 BMS Differential Pressure Switch Wiring C1
6
2
L
AUTO RESET STAR POINT
OVER-HEAT NO NEUTRAL CONNECTED
Key:
CUT-OUT
AIR-FLOW PROVING SWITCH
5
1
PIPED TO OUTSIDE
Mandatory Customer Connection
BROWN
BLACK
Optional Customer Connection
GREY
BLUE
1
3
2
NOTE: RECEIVER MAY BE IN SERIES WITH
BROWN
+ + OR - LEG OF CONTROL LOOP +
POWER
PDGAUGE2/BMS RECEIVER (RL) SUPPLY BROWN
2A
10-35 VDC
- - EARTH BOLT
1 2 5 6 3 4 E N L1 L2 L3 E
RL MAX = VPS - 10.0V

20 mA DC
0-10V
0V
REMOTE FUSED 400V
X MAXIMUM VALUE (1250) Y START SCREENED POWER SUPPLY
SIGNAL TEMPERATURE FROM LOCAL ISOLATOR
CONTROL INPUT
HEATER TRIPPED
4.1.4 Bulkhead Lights VOLT-FREE SIGNAL
CLOSED = HEALTHY
OPEN = TRIPPED
Lights are designed for permanent connection to fixed wiring. This
should be either a suitable lighting circuit (protected with a 5 or 6 Amp 4.1.6 Thermal Wheel
MCB or fuse) or a fused spur (with a 3 Amp fuse) via a fused connection
unit. The thermal wheel incorporates a purge section and is fitted with a
rotational drive. Any temperature sensors and enabling signal are to be
15 Bulkhead Light Wiring provided by others.
Key: A frequency converter with a modular design is used as the control
Internal Factory Connection unit; it can adjust the speed of three-phase motors. The control unit is
Mandatory Customer Connection delivered ready for operation with the factory-set parameters. Various
settings can be changed with an optionally available operating unit.
N Error messages can be read out directly at a flashing LED.
EARTH The power unit is protected from under voltage, over voltage or
FROM
LIGHT L non-approved converter temperature.
TO
INTERNAL
Recommended tightening torque on terminals 0.5 Nm; maximum
1 2
LIGHT tightening torque 0.8 Nm.
COM
MicroMax370
EARTHING
LOOP
Maximum motor power kW 0.37
Output Nominal output current A 1.9
Mains Motor
230V N L E Side Maximum output voltage V 3 x 0-230
50Hz Output frequency Hz (Fixed)4...40-100/150
4.1.5 Electric Heater Wiring Rated voltage V 1x230-240 +/-15%

Mains
Mains frequency Hz 50/60
For models with electric heating, the heating circuit is powered by a Input
higher current, 400Vac 50Hz 3 phase & Neutral supplies. This must be Fuses AT 10
isolated to the unit and fitted with appropriate overcurrent protection. Protection rating IP54
The main supply is still required. Electric heater elements are protected General
by a fail-safe over-temperature switch which will disconnect the heater Ambient temperature °C -20…45
Data
supply if a temperature of 80°C is reached. Once the elements cool, the Air humidity kg 1.1
switch will reset but a power cycle is required to reset the heater supply
Dimensions HxWxD mm 198 x 164 x 60
contactor.
8
17 Typical Thermal Wheel Wiring 5.2 Fan and Motor
2 3
Care should be taken to ensure that the fan and motor run freely and
(Max 8 A /
250 V AC) that the fan is rotating in the correct direction.
Manual
speed The electrical current being drawn by motors should not exceed the
manufacturers recommendations (specified on the motor plate). If
L N U V W T T 13 14 15 2 3 9 10 the current exceeds this, check the fan volume flow rate and the static
1 2 3 4 5 w br
resistance.
M s
Inverters should be configured to match the design and running
3~
+ - frequency that is provided on the datasheet of each specific fan.
1 x 230 V 3 x 230 V Thermal 0-10 V Rotation
Max 180 W contact monitor
! 6.0 MAINTENANCE
Terminal Description Before commencing work make sure that the unit is electrically
L, N, PE Input Voltage - Protective earth must always be connected. isolated from the mains unit and sufficient time has passed to
allow the fans to run down.
U, V, W Motor - 3Ph induction motor wired for 3x230V.
Direction of rotation is changed by switching 2 of the phases. It is important that maintenance checks are recorded and that the
T, T Thermal Contact - Protects motor from overheating. Must be
schedule is always adhered to, in all cases, the previous report should
jumped if the temperature switch is not connected. be referred to.
13, 14, 15 Alarm Relay - Closes between 14-15 on Alarm or Motors are fitted with ‘sealed for life’ bearings and do not require any
voltage drop-out. Max 8A resistive load / 250 V AC. lubrication.
2, 3 Input Signal - 0-10 V. Terminal 2 positive, Terminal 3 negative. 6.1 Fans
Magnet installed with south side (S) towards transmitter. Max.
gap 15mm. Please refer to general arrangement drawings for details of the type
of fan and drive that is fitted. Maintenance guidelines for all fans are
9, 10 Rotation Monitor - White to Terminal 2, Brown to Terminal 3
beyond this manual, please contact Nuaire for specific documents.
A1, A2 Manual Speed - Max RPM when closed regardless of input signal.
Before any work is carried out, please ensure that:
5.0 COMMISSIONING •The power supply to the motor is switched off.
Before commissioning the unit, ensure that all equipment has been •The fan impeller is at rest.
assembled in accordance with the installation procedure all instances
where the unit is in operation the access doors should remain closed; at •The unit power supply is isolated to prevent uncontrolled
no time, during maintenance or otherwise, should anyone be inside a running of the fan during maintenance work.
unit whilst it is in operation. In general, fans should be inspected twice a year, and care should be
5.1 Commissioning Checklist taken to ensure that any unusual vibration or sound is investigated as
an urgent matter. In cases of heavy duty operation, maintenance
•All equipment received is according to specification/order. intervals are to be established by the operator.
•Any damage to unit identified. Access to the fan section is via hinged or lift-off panels. Cable entry
•Fan base shipping restraints / Fixing Brace removed (if applicable). must be made through the apertures provided. Screwed glands with
cable restraint devices should be used.
•The correct installation procedure has been carried out in
accordance to Nuaire’s recommendations. 6.1.1 General Fan Maintenance
•Any fan and thermal wheel motor pulleys are properly aligned. •Access to the fan is normally gained by opening the hinged
access doors, in some instances there will be a turn mechanism
•Anti-vibration mounts are adjusted accordingly. (1/4 turn) to release and lift panels.
•Check / adjust fan and thermal wheel belt tension. •Care should be taken to remove any build-up of dust (a light
•Rotate fan impellers and motors to ensure they run freely. vacuum or light brushing will normally take care of this) Do
not use a steam or any other high pressure cleaners.
•Check any additional bearings and couplings (where fitted
manually). •Inspect the connection between the fan and unit for any
damage or wear and tear.
•Condensate drain traps are checked. Check all filters are correctly
fitted. Ensure ductwork is complete. •Check all fixings are secure.
•Check electrical supply voltage and tightness of all electrical •In accordance with BSEN1886:2007 access doors to the fan
connections. modules are lockable. As such, it must be ensured that a
padlock is used to prevent access when fan is in operation, or
•Ensure control damper operation. coming to rest (padlock supplied by others).
•Ensure access panels and doors are fitted properly and secure. 6.1.2 Bearings
•Check fan motor current draw. Fan bearings should be manually checked at regular intervals for
condition. Standard fan bearings are supplied as ‘sealed for life’ and
have an anticipated life of 40,000 hours.
9
6.1.3 Rotation 6.6 Plate Heat Exchangers
Ensure that the directions of rotation of the driving motor are checked The plate heat exchanger block is normally protected from dust and
and operating correctly. contamination by upstream pre-filters. It is possible to clean the unit
with compressed air in the case of dust deposits or by spraying with a
6.2 Filters mild detergent solution for grease deposits.
When removing the filter access panels, pay attention to the airflow Solvents, strong alkaline, acidic or any products that may be aggressive
direction marked on the panel, this must be replaced to the exact to aluminium or plastics should not be used. Do not use cleaning water
position prior to being removed. Disposable filters should be checked, over 50°C.
and changed when they become fully laden with dust. Washable filters
should be removed and washed in a mild detergent, flushed with clean Drain lines should be checked to ensure that they are unobstructed and
water and allowed to dry before refitting. free draining. Traps should be checked that they are fully primed and
functioning.
6.3 Humidifiers
Drain pans should be flushed out periodically to remove contamination,
Any areas of corrosion should be identified and repaired, any sediment and chemical treatments may be used to provide protection between
from the drain tray and connections should also remain clean. service visits.
6.3.1 Spray Coil/Washer Humidifier Module 6.7 Thermal Wheel Heat Exchangers
All nozzles should be checked and cleaned as necessary. After the 2-3 weeks of operation, and at least once per year, ensure the
Care should also be taken to ensure that the pump is handling the following maintenance is performed.
correct volume of water and is in smooth and quiet operation. The •Check that rotor is vertical and centred in casing. Adjust vertical
pump inlet strainer should also be clean. Check for leaks, pay special and horizontal position if needed.
attention to the shaft seal.
•Check the thermal wheel spins freely.
Remove all filters and clean and ensure that the motor is not
overheating. •Adjust sealing to ensure contact with the rotor and side plates.
Replace brush sealing if it is worn.
6.4 Coils
•Check that motor bracket is in 20-45° angle from horizontal line.
6.4.1 Water
•Adjust length of drive belt if needed.
Water coils should be connected to ensure that full counter flow exists
•Check condition of belt and belt lock (joint).
i.e. - the entering airflow meets the return connection.
18 Thermal Wheel Belt
All water coils should be connected with the flow at the bottom and
the return at the top unless otherwise advised. Drain and bleed valves
are located on the coil, others may be required in the system pipework
depending on the installation.
Frost protection must be incorporated on shut down and fresh air
conditions to avoid coil freezing. Ideally, where the system is at risk of
frost damage, the addition of a proprietary antifreeze solution to the
water is recommended.
Pipe-work connections should be made to the unit using appropriate 20-45°
techniques, and must be independently supported. The connections
should be pressure tested.
6.4.2 DX
Direct expansion coils must be fitted with a correctly sized thermostatic
6.8 Legionella Check
expansion valve with an external equalising connection.
Legionella risk management should be undertaken by a competent
The expansion valve phial must be fitted between the suction header
person appointed by the duty holder in accordance with the latest
connection and the equalising line. The recommendations of the TE
edition of the HSE approved code of practice L8 Legionnaires' disease,
valve manufacturer should be referred to when locating the phial and
the control of legionella bacteria in water systems.
adjusting the superheat. In all cases, settings should be in accordance
with the recommendations of the manufacturer of the refrigeration Particular attention should be given to:
equipment.
•Exhaust heat recovery coil.
All cooling coil drains must be connected to the sloping drain with a
•Cooling coil.
correctly sized trap running to an open tundish or similar.
•Humidifier condensate drip tray water.
6.5 Gas Fired Heater
•Evaporative humidifier.
If a gas fired heater is intended to be used with low air on temperature
please discuss with Nuaire prior to order placement to ensure a suitable •Cooler drains.
component selection.
•Water reservoirs.
10
6.9 Electric Heaters 7.0 WARRANTY
An Air handling unit would normally require no heater maintenance. The 1 year warranty starts from the day of delivery and includes parts
However a periodic check is advised to ensure that the fasteners and and labour for the first year.
electrical connections are operating correctly.
This warranty is void if the equipment is modified without
It is strongly recommended that an airflow switch is incorporated authorisation, is incorrectly applied, misused, disassembled, or not
within the control system with a fan run on timer (15 minutes) and an installed, commissioned and maintained in accordance with the details
interlock provided between the heater contactor and fan motor starter contained in this manual and general good practice.
allowing elements to cool on shut down.
The product warranty applies to the UK mainland and in accordance
6.10 Bulkhead Lights with Clause 14 of our Conditions of Sale. Customers purchasing from
Ensure that lights are switched off and isolated before checking or outside of the UK should contact Nuaire International Sales office for
changing the lamp. further details.
Failure to maintain the unit as recommended will invalidate the
6.11 Specialist Equipment
warranty.
Contact Nuaire for maintenance of specialised equipment that
would have been specified during design stage. A breakdown of the 8.0 END-OF-LIFE AND RECYCLING
component parts can be found on the design specification documents,
Where possible Nuaire use components which can be largely recycled
additional maintenance literature is available, please contact Nuaire.
when the product reaches its end-of-life:
This applies to any components not specifically mentioned in this
document. •Fans, motors, controls, actuators, cabling and other electrical
components can be segregated into WEEE recycling streams.
6.12 Maintenance Schedule
•Sheet metal parts, aluminium extrusion, heating/cooling coils and
6.12.1 Routine Maintenance other metallic items can be segregated and fully recycled.
•Clean all areas of unit and treat any areas of corrosion. •EPP, plastic ducting, nylon corner pieces, plastic heat exchangers,
•Check all access doors for leakage and if necessary locks should be packaging material and other plastic components can be
adjusted and any replacement gasket materials should be replaced segregated into mixed plastic and widely recycled.
as required. •Cardboard packaging, wood, used filters and other paper
•Any drain trays should be cleaned and repaired if necessary. components can be largely recycled or fully processed in energy
from waste centres.
•All dampers should be rotated and lubricated as necessary.
•Remaining Items can be further segregated and processed in
6.12.2 Every 3 Months accordance with the zero waste hierarchy. Please call After Sales
•Check filters and change/clean if required, failure to do so may Support for further information on items not listed above.
impair the performance and energy efficiency of this unit. Ensure that Nuaire product is made safe from any electrical / water
•Ensure condensate drains are cleaned clear and that water can / refrigerant supplies before dismantling commences. This work
flow freely from unit. should only be undertaken by a qualified person in accordance with
local authority regulations and guidelines, taking into account all
•Check fin coil banks and heat exchangers. If necessary clean with a site based risks.
soft brush or vacuum. Check for signs of contamination.
9.0 AFTER SALES AND REPLACEMENT PARTS
6.12.3 Annually
For technical assistance or further product information, including spare
•Thoroughly inspect the unit and its components for corrosion, parts and replacement components, please contact the After Sales
acting immediately to treat/restore any damaged areas. Department.
•All electrical terminals within the unit should be tightened. If ordering spares please quote the serial number of the unit together
•Check all earth connections. with the part number, if the part number is not known please give a full
description of the part required. The serial number will be found on the
•Check control dampers blades. identification plate attached to the unit casing.
•Check operation of damper actuators and linkages and adjust as
necessary.
•Coil faces should be inspected and any dust removed.
Telephone 02920 858 400
•Check any thermal wheel belt, motor, bearings, seals and if aftersales@nuaire.co.uk
necessary clean with a soft brush or vacuum cleaner.
Technical or commercial considerations may, from time to time,

make it necessary to alter the design, performance and dimensions
of equipment and the right is reserved to make such changes without
prior notice.
11
10.0 SERVICE CHART
3 / 9 Month Service 6 Month Service 12 Month Service
Date Date Date
Symbol Action Action Action
Initials Initials Initials
Damper Check the damper Check the damper Clean the damper.
/ Air performance. 3 performance. Check the damper
recirculation performance.
section
9
Filter Check the pressure Check the pressure Check the pressure drop and
drop and change the 3 drop and change the change the filter if necessary.
filter if necessary. filter if necessary.
Thermal Rotor Spins Freely. Adjust sealing to Check that rotor is vertical
Wheel 3 ensure contact with and centred in casing. Adjust
Check condition of
Heat the rotor and side vertical and horizontal
belt and belt lock
Exchanger plates. Replace brush position if needed.
(joint).
sealing if it is worn.
9 Check that motor bracket
Adjust length of drive is in 20-45° angle from
belt if needed. horizontal line.
Plate Heat General inspection. Clean the heat Clean the heat exchanger unit,
Exchanger Check the damper 3 exchanger unit. damper and casing.
performance.
Heat Pipe General inspection. Clean the finned unit. Clean the finned unit, damper,
Exchanger Check the damper 3 drain tray and casing.
performance.
Air Heaters General inspection. Clean the finned unit

Air Coolers 3 and the electric heater
elements.
Humidifier Inspect the: Inspect the: Inspect the:

Casing, Humidifier Casing, Humidifier fills, Casing, Humidifier fills,
3
fills, Droplet Droplet eliminator, Droplet eliminator, Water
IHUMID eliminator, Water Water filter, Water filter, Water tray, Spray pipes,
filter, Water tray, tray, Spray pipes, Water trap, Water quality,
Spray pipes and Water trap, Water flow Water flow and Constant-
Water flow. 9 and Constant-flow flow valve.
valve.
Fans General inspection. General inspection. Clean the fan impeller,
3 casing, unit casing. Check the
bearings.
Casing Check that the doors are tight.

Clean inside and outside if
necessary.
12
DECLARATION OF INCORPORATION AND INFORMATION FOR SAFE INSTALLATION,

OPERATION AND MAINTENANCE
We declare that the machinery named below is intended to be assembled with Signature of manufacture representatives:
other components to constitute a system of machinery. All parts except for Name: Position: Date:
moving parts requiring the correct installation of safety guards comply with the
essential requirements of the Machinery Directive. The machinery shall not be 1)C. Biggs Technical Director 26. 01. 11
put into service until the system has been declared to be in conformity with the
provisions of the EC Machinery Directive.
2)A. Jones Manufacturing Director 26. 01. 11
Designation of machinery: BOXER
Machinery Types: Air Handling Units
Relevant EC Council Directives: 2006/42/EC (Machinery Directive)
Applied Harmonised Standards: BS EN ISO 12100-1, BS EN ISO 12100-2,
BS EN60204-1, BS EN ISO 9001,
BS EN ISO 13857 Note: All standards used were current and valid at the date of signature.
Applied National Standards: BS848 Parts 1, 2.2 and 5
INFORMATION FOR SAFE INSTALLATION, OPERATION AND MAINTENANCE

OF NUAIRE VENTILATION EQUIPMENT
To comply with EC Council Directives 2006/42/EC Machinery Directive and 2014/30/EU (EMC).
To be read in conjunction with the relevant product documentation (see 2.1)
5.0 INSTALLATION REQUIREMENTS
1.0 GENERAL
In addition to the particular requirements given for the individual product, the following
1.1 The equipment referred to in this Declaration of Incorporation is supplied by Nuaire to
general requirements should be noted.
be assembled into a ventilation system which may or may not include additional
5.1 Where access to any part of equipment which moves, or can become electrically live are
components.
not prevented by the equipment panels or by fixed installation detail (e.g. ducting), then
The entire system must be considered for safety purposes and it is the responsibility of
guarding to the appropriate standard must be fitted.
the installer to ensure that all of the equipment is installed in compliance with the
5.2 The electrical installation of the equipment must comply with the requirements of the
manufacturers recommendations and with due regard to current legislation and codes
relevant local electrical safety regulations.
of practice.
5.3 For EMC all control and sensor cables should not be placed within 50mm or on the same
2.0 INFORMATION SUPPLIED WITH THE EQUIPMENT metal cable tray as 230V switched live, lighting or power cables and any cables not
intended for use with this product.
2.1 Each item of equipment is supplied with a set of documentation which provides the
information required for the safe installation and maintenance of the equipment. 6.0 COMMISSIONING REQUIREMENTS
This may be in the form of a Data sheet and/or Installation and Maintenance instruction.
6.1 General pre-commissioning checks relevant to safe operation consist of the following:
2.2 Each unit has a rating plate attached to its outer casing. The rating plate provides
Ensure that no foreign bodies are present within the fan or casing.
essential data relating to the equipment such as serial number, unit code and electrical
Check electrical safety. e.g. Insulation and earthing.
data. Any further data that may be required will be found in the documentation.
Check guarding of system.
If any item is unclear or more information is required, contact Nuaire.
Check operation of Isolators/Controls.
2.3 Where warning labels or notices are attached to the unit the instructions given must be
Check fastenings for security.
adhered to.
6.2 Other commissioning requirements are given in the relevant product documentation.
3.0 TRANSPORTATION, HANDLING AND STORAGE
7.0 OPERATIONAL REQUIREMENTS
3.1 Care must be taken at all times to prevent damage to the equipment. Note that shock
7.1 Equipment access panels must be in place at all times during operation of the unit, and
to the unit may result in the balance of the impeller being affected.
must be secured with the original fastenings.
3.2 When handling the equipment, care should be taken with corners and edges and that
7.2 If failure of the equipment occurs or is suspected then it should be taken out of service
the weight distribution within the unit is considered. Lifting gear such as slings or ropes
until a competent person can effect repair or examination. (Note that certain ranges of
must be arranged so as not to bear on the casing.
equipment are designed to detect and compensate for fan failure).
3.3 Equipment stored on site prior to installation should be protected from the weather and
steps taken to prevent ingress of contaminants. 8.0 MAINTENANCE REQUIREMENTS
8.1 Specific maintenance requirements are given in the relevant product documentation.
4.0 OPERATIONAL LIMITS 8.2 It is important that the correct tools are used for the various tasks required.
8.3 If the access panels are to be removed for any reason the electrical supply to the unit
4.1 It is important that the specified operational limits for the equipment are adhered to
must be isolated.
e.g. operational air temperature, air borne contaminants and unit orientation.
8.4 A minimum period of two minutes should be allowed after electrical disconnection before
4.2 Where installation accessories are supplied with the specified equipment e.g.
access panels are removed. This will allow the impeller to come to rest.
wall mounting brackets. They are to be used to support the equipment only.
NB: Care should still be taken however since airflow generated at some other point
Other system components must have separate provision for support.
in the system can cause the impeller to “windmill” even when power is not present.
4.3 Flanges and connection spigots are provided for the purpose of joining to duct work
8.5 Care should be taken when removing and storing access panels in windy conditions.
systems. They must not be used to support the ductwork.
4.4 Local Environment - Humidity. Ambient humidity (the humidity at the unit’s installed
location) shall be within the range: 10 to 95% (for controls, non-condensing).
Air humidity (the humidity of the air passing through the unit) shall be within the
range: 10 to 95% (for controls, non-condensing).
13
NOTES
14
NOTES
15
NOTES
16

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BESPOKE BOXER

Air Handling Units

be indicated by labelling where appropriate.

following appropriate risk assessment.

3.5 Thermal Wheel Transport Packing

3.6.1 Ductwork 6 Condensate Connections For Vertical Units With PHX

3.8.3 Panel & Bag Filters with Front Withdrawal

Transit Transit Bracket

PE PE Earth connection, PE connection

KL2 2 COM Status relay; floating status contact; changeover contact;

KL2 3 NC Status relay, floating status contact; break with error

KL3 5 + 10 V Fixed voltage output 10 VDC, +10 V ±3%, max. 10 mA,

KL3 7 Din1 Digital input 1: enabling of electronics, Enabling: open pin

KL3 12 + 20 V Fixed voltage output 20 VDC, +20 V +25/-10%, max. 50 mA,

KL3 13 Ain2 I Analogue input 2, actual value: 4-20 mA, Ri = 100 Ω,

Mandatory Customer Connection

NOTE: RECEIVER MAY BE IN SERIES WITH

RL MAX = VPS - 10.0V

4.1.5 Electric Heater Wiring Rated voltage V 1x230-240 +/-15%

Technical or commercial considerations may, from time to time,

Air Heaters General inspection. Clean the finned unit

Humidifier Inspect the: Inspect the: Inspect the:

Casing Check that the doors are tight.

DECLARATION OF INCORPORATION AND INFORMATION FOR SAFE INSTALLATION,

INFORMATION FOR SAFE INSTALLATION, OPERATION AND MAINTENANCE

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