NuAire BOXER Instruction Manual

NuAire Limited
Western Industrial Estate,Caerphilly,
Mid Glamorgan CF83 1XH
Telephone: [phone]
Facsimile: 02920 887033
Email: [email protected]
www.nuaire.co.uk
Leaflet 670777
APRIL 2000
BOXER
Air Handling Units
Installation
and Maintenance
Introduction
The NuAire Boxer range of Air Handling Equipment
comprises a selection of component modules. Fig 1 shows a
typical arrangement. The modules provide treatment and
conditioning of supply and extract air for general ventilation
systems. Note: To ensure effective operation of a system it
is essential that these instructions are adherred to.
Receipt of equipment
Depending on the order placed with your supplier; the
equipment will either be delivered as separate modules, for ease
of movement and assembly on site, or as full / sectional
assemblies complete with a base frame.
In either case a dimensional drawing of the system will be
supplied (attached to the supply fan module). The installer must
check that the delivered items correspond with those detailed on
the drawing.
Note: when assembling the system, the specified position of the
components with the associated orientation and airflow
directional restraints must be followed.
Lifting, moving and storage of equipment
When moving the units follow the procedure as shown in the
diagrams. Do not attach lifting devices other than those shown.
When using slings ensure that spreaders are employed to
prevent damage to the unit casings.
Equipmentshouldbestoredinadrylocationandprotectedfrom
the accumulation of building dust and debris.
Do not stack the equipment during storage. Ensure that no
impact loads are applied to the equipment
The handles fitted to the side panels of the units are for panel
removal only. DO NOT attempt to move the unit using the
handles.
Note: Avoid the panel handles when lifting. Consider the
centre of gravity of the unit- this is not always central to the unit.
.
.
.
.
.
..
.
.
.
.
.
.
.
.Silencer Flexible
Spigot
Silencer
Chilled Water
Coil
Fan Brackets
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
Feet
Forklift
Slings via spreaders
fitted to unit lifting
eyes. NB. individual
modules only
Palletised
Assembly with
baseframe
Slings via spreaders
fitted to unit with
baseframe
1
Fig. 1 Typical module arrangement shown for
illustrative purposes only.
Fig. 2
Lifting and moving the unit.

Gasket
Module Module
Mounting
foot
c/l of
mounting
fixing
2
Fig. 3 Fitting a cleat
Fig. 4 The mounting foot
Fig. 5 Closure Plates used on Bend and Heat Exchanger modules.
Fig. 6 Simple builders upstand mounting assembly.
Installation Options
The Boxer range can be installed using a number of
different methods. This provides flexibility to cater for
particular on site conditions. Note that for units delivered as
individual modules; the spigot plates that connect with the
ductwork are always fitted to the fan module. These should be
removed in preparation for fitting to the appropriate modules at
each end of the assembly.
Assembly of the modules
The module to module assembly is similar for all the unit sizes.
Each module is constructed from six panels. End panels are
designed to attach to the corresponding panel in the adjacent
module and provide mounting points for the assembly.
The modules are assembled together using cleats, mounting
feet or, for certain modules, closure plates.
All fixings necessary are provided. The fixings are vibration
proof.
Clamping cleats are manufactured in heavy gauge mild steel
and are designed to draw the end panels together into the
correct position for gasket compression. For fitting, slacken the
relevant vibration-proof bolts to show approximately 4mm of
exposed thread and slide the cleat into position. A sharp blow to
the folded edge will then engage the cleat. (See fig. 3). Tighten
the bolts to a torque of .........Nm.
Mounting Feet, pressed in mild steel, provide for both
attachment and mounting of the assembly. The vibration proof
bolts should be tightened to a torque of ........Nm.
Closure Plates, are supplied with the Bend Modules and also
the Heat Exchanger Modules. The vibration proof bolts should
be tightened to a torque of ........Nm.
NOTE:
In all cases when positioning adjacent modules, ensure
that the gasket material is not displaced.
Unit Mounting (floor or roof)
On a smooth and level surface, capable of supporting the
assembled weight of the units, no assembly frame is required.
This has the advantage of minimising the overall height of the
unit.
An uneven mounting surface will impose undue strain upon
the assembly. In extreme cases this may cause leakage and
component failure. A simple builders work upstand may be
used to raise the equipment from the floor level. (See fig. 6).
Note: this will be necessary where cooling coils and heat
exchangers are specified in order to allow fitting of the
appropriate condensate drainage trap.
Construct the upstand to support the base periphery of the
assembly. Position the modules in the correct order and a
assemble using clamping cleats. Mounting feet should be used,
at least at every other joint, secured to the mounting surface. It
is normal practice to fit a resilient matting between the unit and
the mounting surface.
Where supplied with a base frame the module assembly needs
only to be positioned and secured to the floor. Again, the
surface should be level and additional height may be required
for drainage traps.
Assemblies are supplied in maximum lengths of 2.4metres.
Longer assemblies must be joined on site (fixings supplied).
Gasket
Module
Cleat
Module
o
o
o
o
o
o
oo
Timber securing battens
used to retain the assembly
in position.
Note that the battens must
not be placed too high
around the assembly which
would interfere in removal
of the side access panels
Installation & Maintenance BOXER AIR HANDLING UNITS

Fig.7 Suspended and wall mounting typical arrangements.
High level mounting
For suspended mounting the installer must consider safe
working access for construction and also subsequent
maintenance, with particular regard to removal of access panels.
For baseframe mounted assemblies, the installer must provide a
series of level supports for attachment of the baseframe.
Supports of cantilever or drop rod design must be adequately
sized and securely fixed.
Supports should be evenly distributed along the length of the
assembly with a recommended maximum span between
supports of 1.5metres. Not more than 150mm of baseframe
should overhang the outermost supports.
Note that the baseframe / module assembly as supplied has a
maximum length of 2.4 metres. For longer assemblies, both the
modules and the baseframe will need to be joined on site
(fixings are supplied).
Where modules are to be individually mounted on site, the
installer must adopt the following systemmatic procedure.
Supports are required at each extreme end of final assembly
and at every second joint for B4 size units and at every joint
for B5,6 and 7 units.
Installation procedure
a) Fit the first two supports at one end of the assembly.
b) Fit mounting feet to the unit. Lift the unit onto the
supports and secure with fixings.
c) Install the third support.
d) Lift the second module into place and attach it to the
mounting feet. Attach the free end to the third support.
e) Fit cleats to the first joint.
f) Continue the procedure until all modules are in position
checking each joint is properly aligned.
g) Check the torque of all bolts and that the fixings to the
supports are secure.
Ensure that the supports do not impose any undue loads on
the component due to misalignment.
Note that when installing a module near to a wall, sufficient
clearance must be allowed for fitting of the mounting feet and
access to the fixing bolts.
Connecting the ductwork.
Assuming the assembly of the modules is complete, the spigot
plates may now be fitted to the outer modules. All fixings are
supplied.
The flexible connectors may now be connected to the
ductwork. The weight of the ductwork should be separately
supported. The ductwork should also be properly aligned with
the connecting spigots. Flexible spigots should be extended so
that they do not impede the airflow but flexibles must not be
stretched as this could allow the transmission of vibration.
To achieve the rated airflow performance there should be at
least 1 metre of straight ducting at both ends of the module
assembly and any bends or restrictions should be positioned as
far away from the unit as is possible.
Installation & Maintenance BOXER AIR HANDLING UNITS
.
.
..
.
Cleat
Mounting
foot Drop rod suspended mounting.
Note: Spacing of supports coincides with module length
Wall bracket mounting.
Module requirements
General
All access panels are secured by M6 x 50 screws which are
retained in the panel. During routine maintenance only one
access panel at any time should be removed from the unit.
When a panel is removed, the condition of the sealing gasket
tape should be checked and replaced if necessary.
Before attempting any maintenance on any component in the
system, THE ENTIRE SYSTEM MUST BE
ELECTRICALLYISOLATED using lockable isolators.
3

Unit codes, dimensions and weights
NOTE:
Where handles and or mounting
feet are used the overall width of
the module is effectively increased
by 50mm each side (100mm
overall).
The unit base frame, where
supplied, increases the overall
height by 150mm and the overall
width by 120mm.
Length
(mm)
700
700
700
700
700
700
700
400
400
400
400
400
400
400
400
400
400
400
700
1000
160
160
1000
700
Width
(mm)
684
684
684
684
684
700
701
684
684
684
684
684
684
684
684
684
684
684
684
1450
620
620
684
684
Height
(mm)
476
476
476
476
476
476
476
476
476
476
476
476
476
476
476
476
476
476
476
476
415
415
476
476
Access requirements (mm)
Top Bottom side
ACCESS REQUIREMENTS
The dimensions shown in the
tables are the minimum required to
effect complete removal of all
serviceable components.
Note that when removing heating
and cooling coils from the side of
the module is is necessary to
remove either the base or top
panel. Therefore allow 40mm min-
imum clearance above or below the
appropriate panel.
B4 Direct Drive
Description Module
Code
B4-F1
B4-F2
B4-F3
B4-SIL
B4-FLP
B4-FLB5
B4-FLB7
B4-EH4/1
B4-EH6/1
B4-EH-6/3
B4-EH12/3
B4-EH18/3
B4-LW1
B4-LW2
B4-LW3
B4-LW4
B4-CW3
B4-CW4
B4-MB
B4-HX
B4-D
B4-DM
B4-V
B4-H
41
43
45
36
34
35
35
23
23
23
23
23
28
36
44
52
42
51
50
83
14
118
38
38
Length
(mm)
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
700
700
700
700
400
400
400
400
400
400
400
400
400
400
400
400
700
1235
160
160
700
1000
Width
(mm)
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
1450
620
620
684
684
Height
(mm)
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
560
560
620
620
Access requirements (mm)
Top Bottom side
FAN
Fan Module
Fan Module
Fan Module
SILENCER
PANEL FILTER
EU3
BAG FILTER
EU5
EU7
ELEC. HEATER
4kW 1Phase
6kW 1Phase
6kW 3Phase
12kW 3Phase
18kW 3Phase
LPHW HEATER
1 Row
2 Row
3 Row
4 Row
CHILLER
3 Row (water)
4 Row (water)
MIXING BOX
HEAT EXCH.
DAMPER
MOD. DAMPER
VERT. BEND
HORIZ. BEND
Weight
(Kg)
Description Module
Code
B5-F1
B5-F2
B5-F3
B5-F4
B5-F5
B5-F6
B5-F7
B5-F8
B5-F9
B5-F10
B5-F11
B5-F12
B5-F13
B5-F14
B5-F15
B5-F16
B5-F17
B5-F18
B5/6-SIL
B5/6-FLP
B5/6-FLB5
B5/6-FLB7
B5/6-EH4/1
B5/6-EH6/1
B5/6-EH6/3
B5/6-EH12/3
B5/6-EH18/3
B5/6-EH24/3
B5/6-LW1
B5/6-LW2
B5/6-LW3
B5/6-LW4
B5/6-CW-3
B5/6-CW-4
B5/6-MB
B5/6-HX
B5/6-D
B5/6-DM
B5/6-V
B5/6-H
83
83
83
83
77
77
77
77
77
77
74
74
73
73
73
73
72
72
44
41
43
43
31
31
31
31
31
31
34
44
53
63
54
63
73
144
12
12
52
52
FAN
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
SILENCER
PANEL FILTER
EU3
BAG FILTER
EU5
EU7
ELEC. HEATER
4.0kW 1Phase
6kW 1Phase
6kW 3Phase
12kW 3Phase
18kW 3Phase
24kW 3Phase
LPHW HEATER
1 Row
2 Row
3 Row
4 Row
CHILLER
3 Row (water)
4 Row (water)
MIXING BOX
HEAT EXCH.
DAMPER
MOD. DAMPER
VERT. BEND
HORIZ. BEND
B5 Belt Drive
Weight
( Kg)
Installation & Maintenance BOXER AIR HANDLING UNITS
4

Length
(mm)
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
1235
700
700
700
700
400
400
400
400
400
400
400
400
400
400
400
400
700
1235
160
160
700
1000
Width
(mm)
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
684
1450
620
620
684
684
Height
(mm)
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
620
560
560
620
620
Access requirements (mm)
Top Bottom side
B6 Belt Drive
Description Module
Code
Weight
(Kg)
B6-F1
B6-F2
B6-F3
B6-F4
B6-F5
B6-F6
B6-F7
B6-F8
B6-F9
B6-F10
B6-F11
B6-F12
B6-F13
B6-F14
B5/6-SIL
B5/6-FLP
B5/6-FLB5
B5/6-FLB7
B5/6-EH4/1
B5/6-EH6/1
B5/6-EH6/3
B5/6-EH12/3
B5/6-EH18/3
B5/6-EH24/3
B5/6-LW1
B5/6-LW2
B5/6-LW3
B5/6-LW4
B5/6-CW3
B5/6-CW4
B5/6-MB
B5/6-HX
B5/6-D
B5/6-DM
B5/6-V
B5/6-H
FAN
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
SILENCER
PANEL FILTER
EU3
BAG FILTER
EU5
EU7
ELEC. HEATER
4kW 1Phase
6kW 1Phase
6kW 3Phase
12kW 3Phase
18kW 3Phase
24kW 3Phase
LPHW HEATER
1 Row
2 Row
3 Row
4 Row
CHILLER
3 Row (water)
4 Row (water)
MIXING BOX
HEAT EXCH.
DAMPER
MOD. DAMPER
VERT. BEND
HORIZ. BEND
94
94
89
89
89
86
86
86
83
83
83
83
80
79
44
41
43
43
31
31
31
31
31
31
34
44
53
63
54
63
73
144
17
17
52
52
Length
(mm)
1420
1420
1420
1420
1420
1420
1420
1420
1420
1420
1420
1420
1420
1420
1420
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
700
1420
1420
160
160
700
1420
Width
(mm)
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
2200
960
960
1000
1000
Height
(mm)
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
750
690
690
750
750
Access requirements (mm)
Top Bottom side
B7 Belt Drive
Description Module
Code
Weight
(Kg)
B7-F1
B7-F2
B7-F3
B7-F4
B7-F5
B7-F7
B7-F8
B7-F9
B7-F10
B7-F11
B7-F12
B7-F13
B7-F14
B7-F15
B7-F17
B7-SIL
B7-FLP
B7-FLB5
B7-FLB7
B7-EH-6/1
B7-EH-8/1
B7-EH-12/3
B7-EH-18/3
B7-EH-24/3
B7-EH-30/3
B7-EH-42/3
B7-LW-1
B7-LW-2
B7-LW-3
B7-LW-4
B7-CW-3
B7-CW-4
B7-CW-5
B7-CW-6
B7-MB
B7-HX
B7-D
B7-DM
B7-V
B7-H
163
163
163
163
163
155
136
136
127
124
124
119
116
116
116
65
63
65
65
45
45
45
45
45
45
45
52
70
85
102
86
103
119
136
116
291
26
26
84
84
FAN
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
Fan Module
SILENCER
PANEL FILTER
EU3
BAG FILTER
EU5
EU7
ELEC. HEATER
6kW 1Phase
6kW 3Phase
12kW 3Phase
18kW 3Phase
24kW 3Phase
30kW 3Phase
42kW 3Phase
LPHW HEATER
1 Row
2 Row
3 Row
4 Row
CHILLER
3 Row (water)
4 Row (water)
5 Row (water)
6 Row (water)
MIXING BOX
HEAT EXCH.
DAMPER
MOD. DAMPER
VERT. BEND
HORIZ. BEND
Unit codes, dimensions and weights
Installation & Maintenance BOXER AIR HANDLING UNITS
5

Electrical information
When selecting suitably sized cable, refer to the table of maxi-
mum running and starting currents. the actual test values for
the module supplied can be found on the module rating label.
Access for wiring is achieved by passing the cables through the
conduit hole which can be found in the module end panels and
fan plate. When routing the cable within the unit, ensure that it
is securely fastened and clear of any moving parts.
On belt drive units the electrical connection is made directly to
the motor terminal box. Flexible conduit should be used to
avoid bridging the anti vibration mountings.
Note:
To avoid damage during transit, the anti vibration mountings
are protected by a TRANSIT PACKER located at the rear of
the fan blower scroll which MUST BE REMOVED
BEFORE STARTING THE UNIT.
The fan module must be earthed and the entire installation
must conform to the requirements of the current electrical
regulations.
Installation & Maintenance BOXER AIR HANDLING UNITS
To motor
terminal box
Flexible
conduit
Flexible conduit
Fig.8 Cable connection through end panel of fan unit
Start Up Procedure
Ensure that nothing is obstructing the fan impeller or drive
mechanism and that there are no loose foriegn objects, tools
etc. in the unit assembly or ductwork.
With the access panel placed in position (but not fixed) apply
power to the unit for 10 seconds. Switch off and quickly
remove the panel to observe the directional rotation of the
impeller. DO NOTREACH INTO THE UNIT.
Alter the phase wiring as necessary.
NB. When an inverter control is fitted the connections must be
reversed between the control and the motor.
Replace the panel and start the unit. Note that the motor and
drive are matched to the unit to operate against a given system
resistance. If the system is not complete, or access panels are
removed, the motor output rating will be exceeded and damage
to motor and drive may occur.m .
Wiring Diagrams
FAN MODULES B4-F1, B4-F2, B4-F3
L N
L N
230v 1 ph 50Hz
supply
230v 1 ph 50Hz
supply
L N
Fan terminal
strip
Fan terminal
strip
UNIT WITHOUT SPEED CONTROL
230v 1 PHASE
AUTO TRANSFORMER SPEED CONTROL
230v 1 PHASE
Control
terminal
strip
ELECTRONIC SPEED CONTROLS
230v 1 PHASE
6
L N
L N 1 2 3
L N
Fan terminal
strip
Control
terminal
strip
L N
L N N1 L2 L1

Installation & Maintenance BOXER AIR HANDLING UNITS
Wiring Diagrams
FAN MODULES THREE PHASE BELT DRIVE
U V W
L1 L2 L3
Fan terminal
strip
U V W
L1 L2 L3
Fan terminal
strip
L1 L/L2 N/L3 PE/ U V W Inverter terminal
strip
UNIT WITHOUT SPEED CONTROL
400v 3 PHASE
UNIT WITH SPEED CONTROL FREQUENCY INVERTER
TYPE 3SCINV... MOTORS ABOVE 2.2kW
400v 3 PHASE
Note: Inverter Speed Controls
Full operating and installation instructions are supplied with every inverter
control. The requirements for cabling and earthing specified MUST be
followed in order to avoid electrical interference problems.
Inverter type SCINV.... has RFI filters pre-fitted. For other types, separate
filters may be required to comply with the relevant electromagnetic
compatibility standards.
(NuAire part code RFI2).
7

Installation & Maintenance BOXER AIR HANDLING UNITS
Wiring Diagrams
FAN MODULES SINGLE PHASE BELT DRIVE
FAN MODULES THREE PHASE BELT DRIVE
with TWO SPEED TAP / PAM WOUND MOTORS
(DOL starting both speeds)
Note:
Single phase belt driven fan modules
are not suitable for speed control
8
L N
L N
Fan terminal
strip
UNIT WITHOUT SPEED CONTROL
230v 1 PHASE
NB:
Reversal of rotation is obtained by interchanging any two supply lines.
230v 1 ph 50Hz
supply
NOTE: For D.O.L. `(Direct on line)
operation or Inverter type Speed Control,
wire in DELTA ( )

Installation & Maintenance BOXER AIR HANDLING UNITS
Maintenance
Before commencing work ensure that the electrical sup-
ply is securely isolated.
DIRECT DRIVE FAN MODULES
Maintenance is limited to the cleaning of the fan blades by light
brushing. Gentle handling is essential as the blades are fragile.
All fastenings should be checked for security.
BELT DRIVEN FAN MODULES
Maintenance is limited to the cleaning of the fan blades by light
brushing. Gentle handling is essential as the blades are fragile.
All fastenings should be checked for security.
The condition and tension of the drive belts should be checked
and adjusted or replaced as necessary.
Changing a drive belt.
To replace a belt, remove the two bolts from the motor
mounting furthest from the fan and slacken the remaining two
bolts. Lift the motor plate and remove the belt. Replacing the
belt is the reverse of this procedure.
Adjusting drive belt tension.
To check the correct tension of a drive belt, place a straight edge
across the two pulleys Apply a force perpendicular to the
centrally to the belt of Newtons ( Ibs).
The deflection in the belt should be 16mm per metre of belt
span. (8mm for 500mm etc.). See fig.9.
The tension of the belt should be checked after 24hrs of
continuous running and adjusted as necessary.
Filter modules
Three filter types are available in the boxer range:-
FLP - EU3 Grade panel filter.
FLB5 - EU5 Grade bag filter.
FLB7 - EU7 Grade bag filter.
Ensure that the entire system is electrically isolated before
removing a filter.
The panel filter consists of punched metal frames retaining
the washable filter media. The filters can be withdrawn from
either side of the module. The filter media is lifted from the
frame by loosening the frame clamps. The filter media may
then be washed in warm water with a mild detergent. The filter
must be pulled into shape and laid flat when drying. Ensure the
filter is fully dry before replacement.
The bag filters are clamped against an internal flange on the
module end plates.The filters may be withdrawn from either
the left or right hand of the module and the chosen direction of
withrawal can be configured on site by altering the position of
the clamp and location components. (See fig 10).
Ensure the chosen filter withdrawal direction is suitable for the
installation.
Deflection
Fig.9 Adjusting the drive belt
Fig.10 Bag filter clamping arrangement.
Clamp
strip
Module end
plate
Fixing Screws
Bag filter
9

Installation & Maintenance BOXER AIR HANDLING UNITS
Electrical Heater Module
The electrical heater modules are assembled as an array of
individual 2kW 230v resistance elements.
As supplied, the standard modules are wired as a single step.
Also included is a high temperature cut out which should be
wired in series with the main contactor coil.
In a correctly filtered system, there is no maintenance
requirement for the heater module other than periodic
checking of the fasteners for security.
Note:
If nuisance tripping of the heater occurs, the most likely cause is
the air velocity dropping below the required 1.5 m/s. This may
be due to dirty filters, too low a speed setting or user
adjustments to the system dampers remote from the unit.
Cut out
Element
L N
230v 1Phase 50Hz
Heater
contactor
(not part
of module)
Heater
contactor
(not part
of module)
SINGLE
STEP
Cut out
Element
N L1 L2 L3
SINGLE
STEP
Cut out
Element
N L1 L2 L3
S1 S2 S3 S4 S5 S6
MULTIPLE
STEP
Cut out
Element
L N
230v 1Phase 50Hz
Heater
contactor
(not part
of module)
MULTIPLE
STEP
Three Phase Heater Modules Wiring diagrams (typical)
Full load running current IT=Total Watts
230
Full load running current IT=Total Watts
at 230v 230
IP=Phase current =IT
3
Single Phase Heater Modules Wiring diagrams (typical)
Note:
S1, S3, S5 linked operation
S2, S4, S6 linked operation
For multi-step operation phase
balance must be preserved
10

Installation & Maintenance BOXER AIR HANDLING UNITS
Low Pressure Hot Water Heater Module
and Chilled Water Coils
Each LPHW and CW coil block is supplied with water
connections, a drainage cock and an air bleed valve.
Observe the orientation and airflow direction instructions on
the module.
Note that pipework connections should be separately
supported.
When draining the system some water may remain in the tubes.
It is advisable to remove this residual water by the application of
regulated compressed air.
If coil replacement should become necessary, detach all
pipework and remove the side access panel and either the top or
base panel. The coil may now be lifted over the base panel lip
and withdrawn or, in the case of base panel removal, slacken the
two bolts retaining the coil tray and allow it to move to its
lower position which will allow the coil to slide free.
The chilled water coils also have a condensate drainage tray and
connection. To prevent the pressure differentials between the
inside and outside of the unit assembly from affecting the
condensate drainage it is necessary to provide a trap
arrangement in the drainage pipework.
The depth of the trap is dependent on the actual air pressure at
the coil position.
Where the coil is on the inlet side of the fan, dimension ‘Y’
must be 30mm for every 250Pa of negative pressure.
Dimension ‘X’ should be 40mm.
Where the coil is on the outlet side of the fan, dimension ‘Y’
should be 40mm and dimension ‘X’ should be 30mm for every
250 Pa of positive pressure.
Occasional cleaning of the fins may be necessary. However, ade-
quate filtration should minimise the need for this operation.
When handling the coil, care should be taken to avoid damaging
the fins. Compressed air may be used to blow through the fins.
The drain tray of cooling coils must be cleaned regularly to
prevent the build up of deposits and the drainage system
flushed through.
Heat Exchange Module
This module incorporates a plate type heat exchanger which
requires occasional removal for cleaning.
inside the unit is a condensate collection tray and connections
to drainage pipework.
The heat exchanger block is retained in the unit by a series of
closure plates which must be removed to allow the block to be
withdrawn. (See fig 13).
With the closure plates removed, the block may be drawn out
through the side access panels.
Cleaning the block is best achieved by immersion in warm
(hand hot) water containing a mild detergent. After soaking for
2 minutes a short period of agitation should suffice. Allow the
block to dry thoroughly before replacement.
The condensate tray should be cleaned regularly and the
drainage system flushed through. The condensate drainage
system requires a trap to prevent the unit internal pressures
from affecting the drainage. Refer to the section on the coil
(page ???) for details of the drainage trap.
Bleed
valve
Drain
cock
Flow
connection
Return
connection
Fig.11 Coils detail
Fig.12 Drain trap arrangement.
Fig.13 The heat exchanger block.
YX
Closure plates
Block
11

The mixing box module is fitted with two of the modulating
dampers and may be connected such that when one damper
opens the other damper closes for variable air recirculation
systems
Before operating the damper check for any obvious blade
distortion. During initial operation check that the damper
movement operates smoothly.
Other Modules (Silencers etc)
The other modules in the Boxer range (Silencers and Vertical /
Horizontal Bends) are passive components with no special
installation or maintenance requirements.
For cleaning purposes the unit panels are removable as in the
other modules.
Modules mounting restrictions
Module type Horizontal Vertical Side
Fan B4 size / / /
Fan B6&7 size /
Filter (panel) / / /
Filter (bag) / /
Electric Heater /
LPHW Heater /
CW Coil /
Heat Exchanger /
Damper / / /
Silencer / / /
Bends / / /
Mixing Box / / /
Installation & Maintenance BOXER AIR HANDLING UNITS
Damper Module and Mixing Box Module
The Motorised Dampers supplied with the Boxer range are
designed to be fitted to any of the unit end panels.
Two damper types are available:-
Type ‘D’ these dampers are designed for simple OPEN /
CLOSED operation.
Type ‘DM’ These dampers are fitted with a modulating
damper motor which allows setting of the damper
block position at any point via a control signal.
The Damper Module requires no routine maintenance.
Wiring Diagrams
TYPE ‘D’
230v 1 phase 50Hz
Damper terminal
strip
TYPE ‘DM’
12
1 2 S1 S2 S3 S4 S5 S6
N L1
24 v AC
Damper terminal
strip
1 2 3 4 5
N L1
A
A = 5% )B = 26 .... 89% )
B
Y1= DC 0 - 10v
Y2= 0 - 20v
Phasecut
U = DC 2 - 10v

We declare that the machine named below
conforms to the requirements of EC Council Directives
relating to Electromagnetic Compatibility and
Safety of Electrical Equipment.
Designation of machinery :- BOXER
Machinery Types :- B
Relevant EC Council Directives :- 89/336/EEC, 92/31/EEC (EMC)
73/23/EEC, 93/68/EEC (Low Voltage Directive)
Applied Harmonised Standards :- E50081-1, EN50082-1, EN60204-1
EN60335-2-80
Basis of Self Attestation :- Quality Assurance to BS EN ISO 9001
BSI Registered Firm Certificate No. FM 149
Signature of manufacture representatives :-
Name: Position: Date:
1) C. Biggs Technical Director 3. 3. 00
2) M. Fussell Manufacturing Director 3. 3. 00
NuAire Limited,
Western Industrial Estate,
Caerphilly, Mid Glamorgan,
CF83 1XH. United Kingdom.
Telephone: [phone]
Fax: [phone]
Email: info @ nuaire. co. uk
www.nuaire.co.uk
APRIL 2000
DECLARATION
OF CONFORMITY

We declare that the machinery named below is intended to be assembled with other
components to constitute a system of machinery.
The machinery shall not be put into service until the system has been declared to be
in conformity with the provisions of the EC Council Machinery Directive.
Designation of machinery :- BOXER
Machinery Types :- B
Relevant EC Council Directives :- 98/37/EC (Machinery Directive)
Applied Harmonised Standards :- EN292-1, EN292-2, EN294, EN29001
Applied National Standards :- BS848 Parts One, Two and Five
Signature of manufacture representatives :-
Name: Position: Date:
1) C. Biggs Technical Director 3. 3.00
2) W. Glover Manufacturing Director 3. 3.00
NuAire Limited,
Western Industrial Estate,
Caerphilly, Mid Glamorgan,
CF8 1XH. United Kingdom.
Telephone: [phone]
Fax: [phone]
Email: info @ nuaire. co. uk
www.nuaire.co.uk
APRIL 2000
DECLARATION OF INCORPORATION
& INFORMATION FOR SAFE
INSTALLATION, OPERATION & MAINTENANCE

INFORMATION FOR SAFE INSTALLATION, OPERATION AND
MAINTENANCE OFNUAIRE VENTILATION EQUIPMENT
To comply with EC Council Directives 89/392/EEC Machinery Directive
To be read in conjunction with the relevant Product Documentation (see 2.1)
1.0 GENERAL
1.1 The equipment referred to in this Declaration of Incorporation is supplied by NuAire to be assembled into a ventilation
system which may or may not include additional components.
The entire system must be considered for safety purposes and it is the responsibility of the installer to ensure that all of the
equipment is installed in compliance with the manufacturers recommendations and with due regard to current legislation and
codes of practice.
2.0 INFORMATION SUPPLIED WITH THE EQUIPMENT
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. This may be in the form of a Data sheet and/or Installation and Maintenance instruction.
2.2 Each unit has a rating plate attached to its outer casing. The rating plate provides essential data relating to the equipment such as
serial number, unit code and electrical data. Any further data that may be required will be found in the documentation. If any
item is unclear or more information is required, please contact NuAire.
2.3 Where warning labels or notices are attached to the unit the instructions given must be adhered to.
3.0 TRANSPORTATION, HANDLING AND STORAGE
3.1 Care must be taken at all times to prevent damage to the equipment. Note in particular that shock to the unit may result in the
balance of the impeller being affected.
3.2 When handling the equipment, care should be taken with corners and edges and that the weight distribution within the unit is
considered. Lifting gear such as slings or ropes must be arranged so as not to bear on the casing.
3.3 Equipment stored on site prior to installation should be protected from the weather and steps taken to prevent ingress of
contaminants.
4.0 OPERATIONAL LIMITS
4.1 It is important that the specified operational limits for the equipment are adhered to e.g. operational air temperature, air borne
contaminants and unit orientation.
4.2 Where installation accessories are supplied with the specified equipment eg. wall mounting brackets. They are to be used to
support the equipment only. Other system components must have separate provision for support.
4.3 Flanges and connection spigots are provided for the purpose of joining to ductwork systems. They must not be used to support
the ductwork.
5.0 INSTALLATIONREQUIREMENTS
In addition to the particular requirements given for the individual product, the following general requirements should be noted.
5.1 Where access to any part of equipment which moves, or can become electrically live are not prevented by the equipment
panels or by fixed installation detail (eg ducting), then guarding to the appropriate standard must be fitted.
5.2 The electrical installation of the equipment must comply with the requirements of the relevant local electrical safety regulations.
6.0 COMMISSIONING REQUIREMENTS
6.1 General pre-commissioning checks relevant to safe operation consist of the following -
Ensure that no foreign bodies are present within the fan or casing
Check electrical safety. e.g. Insulation and earthing.
Check guarding of system.
Check operation of Isolators/Controls.
Check fastenings for security.
6.2 Other commissioning requirements are given in the relevant product documentation.
7.0 OPERATIONAL REQUIREMENTS
7.1 Equipment access panels must be in place at all times during operation of the unit, and must be secured with the original fastenings.
7.2 If failure of the equipment occurs or is suspected then it should be taken out of service until a competent person can effect repair
or examination. (Note that certain ranges of equipment are designed to detect and compensate for fan failure).
8.0 MAINTENANCE REQUIREMENTS
8.1 Specific maintenance requirements are given in the relevant product documentation.
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 must be isolated.
8.4 A minium period of two minutes should be allowed after electrical disconnection before access panels are removed. This will allow
the impeller to come to rest.
NB: Care should still be taken however since airflow generated at some other point in the system can cause the impeller to “windmill” even when
power is not present.
8.5 Care should be taken when removing and storing access panels in windy conditions.

16
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.
Western Industrial Estate,
Caerphilly, Mid Glam CF83 1XH
United Kingdom.
Telephone: [phone]
Facsimile: 02920 887033,
Email: [email protected]
www.nuaire.co.uk
Leaflet No. 670777
Installation & Maintenance BOXER AIR HANDLING UNITS