NuAire BPS H-ES Series User manual

1
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Horizontal Boxer Packaged Solution
with EcoSmart Classic (ES) Control
Installation Manual
1.0 SAFETY INFORMATION
• The provision of the electrical supply and the connection of the unit to the mains must be
carried out by a qualified electrician.
• Isolate from power supply before removing any covers. During installation / maintenance ensure
all covers are fitted before switching on the mains supply.
• 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.
• This unit must be earthed.
• 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.
• If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or
similarly qualified persons in order to avoid a hazard.
• Precautions must be taken to avoid the back-flow of gases into the room from the open flue of
gas or other fuel-burning appliances.
• 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.

2
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
1.2 Important Information
This manual contains important information on the safe and
appropriate assembly, transport, commissioning, operation,
maintenance, disassembly and simple troubleshooting of the product.
While the product has been manufactured according to the accepted
rules of current technology, there is still a danger of personal injury or
damage to equipment if the following general safety instructions and
the warnings contained in these instructions are not complied with.
•Read these instructions completely and thoroughly before
working with the product.
•Keep these instructions in a location where they are accessible
to all users at all times.
•Always include the operating instructions when you pass the
product on to third parties.
1.3 Personal Protective Equipment
The following minimum Personal Protective Equipment (PPE) is
recommended when interacting with Nuaire products:
•Protective Steel Toed Shoes - when handling heavy objects.
•Full Finger Gloves (Marigold PU800 or equivalent) - when
handling sheet metal components.
•Semi Fingerless Gloves (Marigold PU3000 3DO or equivalent)
- when conducting light work on the unit requiring tactile
dexterity.
•Safety Glasses - when conducting any cleaning/cutting operation
or exchanging filters.
•Reusable Half Mask Respirators - when replacing filters which
have been in contact with normal room or environmental air.
Nuaire would always recommend a site specific risk assessment by a
competent person to determine if any additional PPE is required.
2.0 INTRODUCTION
The information contained in this document provides details of
installation, operation and maintenance for installers and users of the
BOXER PACKAGED SOLUTION (BPS) AHU units with heat recovery.
The BPS AHU range, is manufactured from Aluzinc corrosion resistant
steel, with 50mm double skinned panels and anodized aluminium
frame of a totally thermally-broken design, complying with the
following specification in accordance with BS EN 1886: Mechanical
strength, D1; Leakage class, L1; Thermal transmittance, T2; Thermal
bridging, TB1.
This range includes high efficiency centrifugal fans with EC motors, a
high efficiency thermal wheel or plate heat exchanger, G4 pre-filtration
and F7 main filtration of the supply air and M5 filtration of the extract
air.
Optional heating (LPHW or Electric) model variants are available.
Ancillaries including but not limited to attenuators, dampers, weather
terminals and frost modules are available from Nuaire.
These units are supplemented with the EcoSmart Classic (ES) control
platform. General information regarding performance and specification
for the equipment is available via our technical literature, and/or
project specific documentation.
2.1 Code Description:
B 8 05 H / L R / ES - L
| | | | | | | |
1 2 3 4 5 6 7 8
1. Range: B = Boxer Packaged Solution
2. ErP Compliance Year: 8 or No Affix = 2018
3. Unit Size: 05, 10, 15 or 20
4. Heat Recovery Type: H = Horizontal Plate
5. Heating Type: E= Electric
L = Low Pressure Hot Water (LPHW)
N = No Heating
6. Cooling Type: N = No Cooling
7. Control Type: ES = Classic
8. Access Handing L = Left Hand
(in direction of supply R = Right Hand
airflow)

3
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
3.0 OPTIONAL ANCILLARIES
1a
Plate Heat
Exchanger
Control
Section
Supply
Module
Electric
Heater
LPHW, DX
or CHW
Filter
4
56
7
Extract
Module
2 or 3
1
Filter
I
N
T
AKE
/
EXHAUST
SUPPLY / EXTRACT
1 Typical Optional Ancillaries
Model shown is right hand
Quick Selection Guide BPS BOXER PACKAGED AHU’s - ANCILLARIES
BPS Unit
Module Part Number Description
Attenuator
1
B**AH/AR900-R BPS size **. Attenuator for Supply/Extract, Right Handed, for Horizontal PHX Units.
B**AH/AR900-L BPS size **. Attenuator for Supply/Extract, Left Handed, for Horizontal PHX Units.
Attenuator
1a
B**AH/AA900-R BPS size **. Attenuator for Intake/Exhaust, Right Handed, for Horizontal PHX Units.
B**AH/AA900-L BPS size **. Attenuator for Intake/Exhaust, Right Handed, for Horizontal PHX Units.
Frost Coil - Electric
2
B**AH/FE-R BPS size **. Frost Coil Electric, 36kW, Right Handed, for Horizontal PHX Units.
B**AH/FE-L BPS size **. Frost Coil Electric, 36kW, Left Handed, for Horizontal PHX Units.
Frost Coil - LPHW
3
B**AH/FL-R BPS size **. Frost Coil LPHW, Right Handed, for Horizontal PHX Units.
B**AH/FL-L BPS size **. Frost Coil LPHW, Left Handed, for Horizontal PHX Units.
Recirculation Module
4
B**AH/RM-R BPS size **. Recirculation Module, Right Handed, for Horizontal PHX Units.
B**AH/RM-L BPS size **. Recirculation Module, Left Handed, for Horizontal PHX Units.
Weather Terminal
5B**AH/RT BPS size **. WeatherTerminal, for Horizontal PHX Units.
Inlet/Outlet Damper
6B**AH/D BPS size **. Inlet/Outlet Dampers suitable for right or left handed Horizontal PHX Units.
Weather Terminal &
Inlet/Outlet Damper
7
B**AH/RTD-R BPS size **. WeatherTerminal & Damper, Right Handed, for Horizontal PHX Units.
B**AH/RTD-L BPS size **. WeatherTerminal & Damper, Left Handed, for Horizontal PHX Units.
** Insert BPS unit size sizes for the relevant ancillary.

4
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
4.0 DELIVERY & RECEIPT OF EQUIPMENT
All equipment is inspected prior to despatch and leaves the factory in
good condition. Upon receipt of the equipment an inspection should be
made and any damage indicated on the delivery note.
Particulars of damage and/or incomplete delivery should be endorsed
by the driver delivering the goods before offloading by the purchaser.
No responsibility will be accepted for damage sustained during the
offloading from the vehicle or on the site thereafter.
All claims for damage and/or incomplete delivery must be reported to
Nuaire within two days of receipt of the equipment.
4.1 Unit Offloading and Handling
The weight of unit modules and palletised items is displayed on the
packaging. Some of the modules have an uneven weight distribution
and this will be indicated by labelling where appropriate.
Offloading and positioning of the equipment is the responsibility of
the purchaser, and should only be performed by competent personnel
following an appropriate risk assessment.
To ensure that the delivery vehicle is loaded according to the
planned method of offloading, Nuaire must be notified to ensure
coordination. 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.
4.2 Base Frame Lifting Points
When units are constructed of multiple modules each module will have
it’s own individual base frame, which is then connected to the next to
assemble the full system.
All base frame sections will have 50mm square lifting holes at the
end of each side to enable lifting. In addition to this, covered fork
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 3).
Only individual modules should be lifted or manoeuvred. The units
must not be lifted or manoeuvred pre-assembled. Actual unit
lifting plan and risks must be assessed by competent personnel
before moving the unit.
3 Base Frame Detail
A
A ( 1:5 )
150.0
50.0
51.5
50.0
51.5
100.0
100.0
86.0
81.0
Overall Unit Length
Section Length Section Length Section Length
Section Width
50.0
50.0
50mm x 50mm Lifting Hole
Palletised. Forklift.
Assembly with
base frame.
2 Typical Methods of Lifting
Slings via spreaders fitted to
unit with base frame.
4.3 Unit Packaging
Unless otherwise specified, unit sections will be delivered to site
covered in “shrink wrap” polythene, which should provide a more than
adequate level of protection against inclement weather.
Should alternative methods of unit protection be required (i.e. timber,
Corex, 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.
4.4 Unit Storage
The equipment must be stored in a dry, internal location. Ductwork
connection apertures should be sealed against the ingress of dust,
water and vermin. Note that units that are intended for external
locations are generally not fully weatherproofed until their installation,
including ductwork connections, is complete.
If the storage period is to exceed two months, contact Nuaire for
guidance on the appropriate ‘mothballing’ procedures. Do not stack
units, modules or components.

5
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
5.0 UNIT ACCESS
In this product range, several unique concepts have been
implemented with a view to simplifying the installation design.
•The unit must be installed with at least 600mm clearance from a
wall/barrier. With this absolute minimum clearance, the unit may
be connected to the power supply and control connection.
•With this clearance, unit filters may be changed, and the fans
coils, heat exchanger and condensate tray may be inspected and
cleaned if necessary.
•The LPHW and Electrical heater settings, coil bleed and drain, and
all other control adjustments are similarly accessible.
•Side access, where possible, is preferred in all cases in terms of safe
working access to the equipment under the CDM regulations.
•Note however, that access in the situation is difficult and
additional time should be allocated. For convenience it is preferred
that wherever possible, this minimum access provision is not
adopted, and it is recommended that a minimum of around
600mm clearance (as stated in ADF 2010) is allowed.
•Where these arrangements are not suitable, the Consultant’s
and Contractor’s project specific requirements will always be
accommodated where possible.
5.1 Hinged / Removable Panel Access
All hinged access panels will be lockable and removable via locked
hinges which can be opened for panel removal. All keys are identical
and will open any handle or hinge.
The hinges do not need to be unlocked in normal operation of opening
and closing.
4 Removable Hinged Access Panel (Hinged)
5 Removable Hinged Access Panel (Removed)
Easily removable
blowers for
maintenance
Access to built-in controls
Interchangeable filters
slide in and out
Hinged or removable
access panels
Access to
Plate Heat Exchanger
Access to interchangeable coils, LPHW
heater and chilled water cooling option
8mm outside diameter
condensate drain.
Condensate pump
fitted as standard
(where necessary).
6 Unit Access

6
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
5.2 Access Areas
5.2.1 Left Hand Units
7 Access For Left Hand Units
Intake
Exhaust
Extract
Supply
Model shown is left handed
EXTRACT
SUPPLY
INTAKE
DISCHARGE
Access
Shown from top (Left hand - L).
Access
CONTROLS
LPHW
600mm
600mm
8 Top View of Access For Left Hand Units
5.2.2 Right Hand Units
Extract
Supply
Intake
Exhaust
Model shown is right handed
9 Access For Right Hand Units
EXTRACT
SUPPLY
INTAKE
DISCHARGE
Access
Shown from top (Right hand - R).
Access600mm
600mm
10 Top View of Access For Right Hand Units

7
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
6.0 MECHANICAL INSTALLATION
Installation must be completed by competent persons, in accordance
with good industry practice and should conform to all governing and
statutory bodies i.e. IEE, CIBSE, etc.
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.
6.1 Unit 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
adjacent to the unit for future inspection, maintenance, component
service, repair and replacement and connection of services. It is
recommended that at least the unit width (vertically arranged units)
+ 100mm be allowed. A minimum of 600mm is required for regular
maintenance.
Sufficient clearance for U-traps on condensate drain and overflow
connections should also be considered by the purchaser.
6.2 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.
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
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.
6.3 Module Joints
After unwrapping, temporarily remove the rubber weatherproof cover
strip and M10 base frame bolts from any modules and store in a safe
location for later use.
Apply the sealing gasket as necessary to the mating faces of the
unit frames. Typically the sealing gaskets are pre-fitted to the heat
exchanger module; ancillary modules will be provided with a roll of
sealing gasket for on-site fitting.
Make the unit joints in the following order:
•Left and right hand side M10 bolts between the modules’ base
frames (Figure 11).
•Left and right hand side M6 Lower 3 axis alignment clamps (Figure
12).
•Left and right hand side M6 Middle 3 axis alignment clamps.
•Left and right hand side M6 Upper 3 axis alignment clamps.
Air leakage, air blow marks to the unit casings and unacceptable
noise levels could result if the correct installation procedures are not
employed.
11 M10 Modular Base Frame Connection Bolt
12 3-Axis Clamp
6.4 Internal Connections
There are a number of internal connections that need to be completed
prior to starting/commissioning the unit. These consist of all the wiring
connections and the condensate hose (plate heat exchanger option
only).
Ensure that the condensate hose is connected between modules. Care
must be taken to ensure a constant fall in gradient is maintained and
the hose is kept taught (Figure 13).
Access is available in the fan plate to allow electrical/wiring
connections to be made between modules (Figure 14).
When making the wiring connections, the sensor loop (Figure 15) must
be removed and relocated to the end of the unit.
13 Condensate Hose Connection

8
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
14 Fan Plate Access Hatch
15 Sensor Loop Connection
6.5 Condensate Drain
Plate heat exchanger components and modules that incorporate
cooling coils may produce condensation during use. An insulated drip
tray and condensate pump is provided where necessary. The drain
connection must be connected to a suitable drainage point.
Condensate pump specification:
Maximum flow rate = 50 L/H
Maximum head = 20m Vertical, 100m Horizontal
Pipe Connection size (Low Pressure Condensate connection) = 8 mm
6.6 Weather Resistant Units
The units are supplied in multiple sections and have weather resistant
roof components that must be fitted and sealed after the unit sections
are bolted together. All necessary fixings are supplied with each unit
and are normally bagged and located within the fan section. Suitable
mastic sealant is to be provided by others.
Where the weatherproof roof assembly of two sections meet, the
metal hinged weatherproof cover strip must be closed to seal the seam
between unit sections and fixed with the bolts provided.
The equipment must not be exposed to the weather in an unassembled
or partially assembled state. All roof terminal, ductwork, sealing and
assembly work must be completed before the unit can be considered
weather resistant.
6.7 Unit Connections
6.7.1 Ducting
Nuaire do not provide ductwork connections with units, instead the
open ended framework should be utilised. Flanged connections are
available as an option, refer to technical documents for information
relating specifically to the manufactured unit.
6.7.2 Coil
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.
Additional care must be taken when using R32 or other flammable
refrigerants: your commissioned system must comply with the
requirements of BS EN 378. Units must be fitted with gas detection
systems (or deploy other suitable control method) to ensure that,
in the event of a refrigerant leak, the Lower Flammability Limit is
not exceeded.
Each coil section should be trapped and special care should be taken to
ensure that there are no vertical rising condense lines, unless pumped.
Wet pipe connections sizes are listed in the table below.
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,
as the fragile pipework will protrude from the side of the unit.
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).
Unit
Size
Frost Coil
(LPHW)
Heating Coil
(LPHW)
Cooling Coil
(CHW)
Flow Return Flow Return Flow Return
05 15 mm 15 mm 15 mm 15 mm 22 mm 22 mm
10 22 mm 22 mm 22 mm 22 mm 22 mm 22 mm
15 22 mm 22 mm 22 mm 22 mm 28 mm 28 mm
20 28 mm 28 mm 28 mm 28 mm 35 mm 35 mm

9
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
6.8 Filters
6.8.1 Filter Removal
Filters will be provided in banks on suitable slide rails, so that they can
be withdrawn from the access side of the unit. Differential "Dirty Filter"
pressure switches are fitted as standard.
6.8.2 Spare Filters
If specified with order, spare sets of filters will be provided and should
be stored in a clean, dry environment. Should you require spare filter
media, please contact Nuaire.
16 Filter Side Withdrawal
6.9 Control Dampers
Care should be taken to ensure that all spring return actuators have
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.
Where dampers are protected with a roof terminal, the roof terminal
can be removed for access to the main damper. Access to the actuator
can be from the side of the roof terminal without the requirement of
removing the roof terminal (Figure 18).
17 Removing Roof Terminal
18 Actuator Access
6.10 Damper / Roof Terminal Assembly
The inlet/outlet dampers and roof terminals are pre-assembled (for BPS
sizes 07, 12 and 17) on a double skinned and insulated panel. The panel
is easily fitted to the unit with a series of quarter turns (provided with a
locking key) (Figure 19).
For the larger size BPS units (22, 32 and 42) the pre-assembled
dampers and terminals are provided with lifting eyes for on-site
hoisting into position (Figure 20).
19 Inlet / Outlet Damper / Terminal Quarter Turn Fixings
20 Inlet / Outlet Damper / Terminal Lifting Eyes (22, 32 & 42)
6.11 Supporting Ancillary Items
All ancillary items that are supplied without individual base frames
require safe suitable support (supplied by others). This includes but is
not limited to single attenuators, terminals and dampers etc.
6.12 Installation 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.
•Remove any transit protection fittings that may be attached to the
fan or motor base frame, and that all traps are primed.
•Close all access door seals for damage, and replace any panels that
have been removed.

10
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
7.0 ELECTRICAL INSTALLATION
The electrical wiring must be carried out by competent persons, in
accordance with good industry practice and should conform to all
governing and statutory bodies i.e. IEE, CIBSE etc.
7.1 Main Unit Power Supply
The control is powered by a 400Vac 50Hz 3 phase & Neutral supply.
This must be isolated local to the unit and fitted with appropriate over-
current and fault protection.
7.2 Electric Heater Power Supply
For models with electric heating, the heating circuit is powered by 1 or
2 separate, higher current, 400Vac 50Hz 3 phase & Neutral supplies.
This must be isolated to the unit and fitted with appropriate over-
current protection. The main supply is still required. Electric heater
elements are protected by a fail-safe over-temperature switch which
will disconnect the heater supply if a temperature of 80°C is reached.
Once the elements cool, the switch will reset but a power cycle is
required to reset the heater supply contactor.
7.3 Power Supply Details - FLC
Unit Size Unit (FLC) Unit with Electric Heater
(Electric Heater Models Only)
B*05H/**ES 4.3 A 4.3 A + 17.5 A †
B*10H/**ES 6.8 A 6.8 A + 35 A †
B*15H/**ES 9.5 A 9.5 A + 52.5 A †
B*20H/**ES 10 A 10 A + 52.5 A †
* Denotes any Character.
† These heater models require a separate power supply for the electric
heater section, with an appropriate over-current protection device.
7.4 Wiring
All inter-connections between circuit boards, blowers and sensors are
made at the factory. This diagram only shows the essential field wiring
points for clarity.
Remove link wire if switched live signal, an enabler or BMS signal is
connected.
If inlet and outlet dampers are fitted, remove the damper link
wires. This will allow a 1 minute delay before starting the fans.
7.4.1 Switch Live
Switch Live (SL) terminal - A signal of 100-230V a.c. will activate the
switch live signal.
Switch Live 2 (SL2) terminal - A signal of 100-230V a.c. will activate the
switch live 2 (Fan Boost) signal.
A signal from an isolating transformer will produce an
unpredictable result and is not recommended.
Extra low voltage versions of the switched live signals are also available.
Link two contacts to activate the signal.
7.4.2 Volt Free Contacts
The volt free contacts are not fused. If these are used to power any
external equipment, the installer must provide adequate fusing or other
protections. These contacts are rated at 5A resistive, 0.5A inductive.
Run connections- Contacts closed when fan is running.
Fault connections- No Fault = contacts are closed.
Fault = contacts are opened.
Heat demand- Contacts closed when heating is selected.
Thermal Wheel Fault Contacts 14, 15
Supply Filter dP NC Contacts 12, 13
Extract Filter dP NC Contacts 10, 11
Pump Fault Contacts
21 Volt Free Contact Wiring
7.4.3 Independent Supply & Extract Speed Control
Remove NET link connection for independent speed control.
Damp
er Connections Run
Signal
Fault
Signal
Min Max SL run
on
Trickle Test
0 1
ES-CO2
Connection
BMS
Input
Signal
0-10V
0V
Ecosmart
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
TX
RX
Extract
N
E
L
SL
DP
CL
N
RET
Link wire see note* Heat
Demand Run Fault
Heat Demand
Signal
Damper Link Volt Free Relay Contacts
Damp
er Connections Run
Signal
Fault
Signal
Min Max SL run
on
Trickle Test
0 1
ES-CO2
Connection
BMS
Input
Signal
0-10V
0V
Ecosmart
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
TX
RX
Extract
N
E
L
SL
DP
CL
N
RET
Link wire see note* Heat
Demand Run Fault
Heat Demand
Signal
Damper Link Volt Free Relay Contacts
NET Link
22 Speed Control NET Link

11
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
7.6 Wiring
All inter-connections between circuit boards, blowers and sensors are
made at the factory. Remove link wire if switched live signal, an enabler
or BMS signal is connected.
If inlet and outlet dampers are fitted, remove the damper link
wires. This will allow a 1 minute delay before starting the fans.
A series of basic connection wiring diagrams have been provided to
assist on-site wiring. In order to reference the relevant diagrams please
use the code breakdown opposite to determine:
•Unit size
•If an electric heater is present
•If a LPHW heater is present
The below tables can then be used to reference the required connection
and wiring diagrams.
Example:
Unit on site has code B820H/EN/ES-L. This indicates a size 20 unit
with electric heating (Section 7.8.5).
7.6.1 Code Description:
B 8 05 H / L R / ES - L
| | | | | | | |
1 2 3 4 5 6 7 8
1. Range: B = Boxer Packaged Solution
2. ErP Compliance Year: 8 or No Affix = 2018
9. Unit Size: 05, 10, 15 or 20
10. Heat Recovery Type: H = Horizontal Plate
1. Heating Type: E= Electric
L = Low Pressure Hot Water (LPHW)
N= No Heating
2. Cooling Type: N= No Cooling
3. Control Type: ES = Classic
4. Access Handing L= Left Hand
(in direction of supply R = Right Hand
airflow)
7.7 Wiring Diagram Reference Table
Unit
Size
Unit Contains
NO Heater
Unit Contains
LPHW Heater
Unit Contains
Electric Heater
05 Section 7.8.1 Section 7.8.2 Section 7.8.4
10 Section 7.8.1 Section 7.8.2 Section 7.8.4
15 Section 7.8.1 Section 7.8.3 Section 7.8.5
20 Section 7.8.1 Section 7.8.3 Section 7.8.5
7.5 Isolator Wiring Points
Main wiring points for the customer is to the isolators situated on
the sides of the units as shown below. Cable glands are for additional
ancillary cabling and are located on the sides of the units.
ISOLATOR POSITIONED ON
ELECTRIC HEATER UNIT
Unit Isolator
23 Isolator Locations
24 Cable Gland Locations

12
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
7.8 Wiring Diagrams
7.8.1 Unit Sizes 05 - 20 with No Heating
25 Unit Sizes 05 - 20 with No Heating Wiring Diagram

13
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
7.8.2 Unit Sizes 05 - 10 with LPHW Heating
Internal interconnections are not shown for clarity.
N
L
SL
OP
CL
N
RET
HEAT
DEMAND RUN FAULTDAMPERSUPPLY
Supply Fan Board
Switched Live Link
Supply Fan Board
IO Damper Link
Remove when IO
dampers are fitted to
enable fan start delay
Relay Outputs
Run relay is used for
thermal wheel /
frost coil enable relay
Extract Fan Board
Switched Live Link
IO Damper Link
Remove when IO
dampers are fitted to
enable fan start delay
OP
CL
N
DAMPER
N
L
SL
RET
RUN FAULTSUPPLY
Heat Exchanger
Bypass Board
Supply Fan Board
ecosmart
Min
Trickle
0 1
Test
Max SL Runon
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Extract Fan Board
Condensate Pump HX
Bypass Relay
Lighting, Thermal Wheel
& Transformer 230Vac
Supply Fan
Contactor
Extract Fan
Contactor
0 24V
+15V 0 -15V 230V 400V
ecosmart
Min
Trickle
0 1
Test
Max SL Runon
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Fan Run Relay
HX Bypass Relay
24Vac Fuse 1.6A
Thermal Wheel Fault
Contacts NC T14, 15 Supply Filter dP Contacts NC T12, 13 Extract Filter dP Contacts NC T10, 11
24Vac 0V
IO Damper Relay
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
NL1 L2 L3 E
Lighting, Thermal
Wheel & 24Vac TR
Controls
Extract Fan Supply Fan
400V 3ph 50Hz
Main Power Supply
Overcurrent
Protection
(By Others)
Local Rotary Lockable IP66/67 Isolator
L1
E
L2 L3 N
L1 L2 L3 N
T1 T2 T3 N
1 2 3 4
Condensate
Pump Fuse 1A
Condensate Pump
Fault Contacts NC
Key:
Factory Connection
Customer Connection (Mandatory)
Customer Connection (Optional)
26 Unit Sizes 05 - 10 with LPHW Heating Wiring Diagram

14
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
7.8.3 Unit Sizes 15 - 20 with LPHW Heating
N
L
SL
OP
CL
N
RET
HEAT
DEMAND RUN FAULTDAMPERSUPPLY
Supply Fan Board
Switched Live LinkIO Damper Link
Remove when IO
dampers are fitted to
enable fan start delay
Relay Outputs
Run relay is used for
thermal wheel /
frost coil enable relay
Switched Live LinkIO Damper Link
Remove when IO
dampers are fitted to
enable fan start delay
Extract Fan Board
OP
CL
N
DAMPER
N
L
SL
RET
RUN FAULTSUPPLY
Supply Fan Board
ecosmart
Min
Trickle
0 1
Test
Max SL Runon
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Extract Fan Board
ecosmart
Min
Trickle
0 1
Test
Max SL Runon
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
0 24V
+15V 0 -15V 230V 400V
Condensate Pump HX
Bypass Relay
Heat Exchanger
Bypass Board
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
ABB
0 0FF
NL1 L2 L3 E
Lighting, Thermal
Wheel & 24Vac TR
Controls
Extract Fan Supply Fan
Fan Run Relay
HX Bypass Relay
24Vac Fuse 1.6A
Thermal Wheel Fault
Contacts NC T14, 15 Supply Filter dP Contacts NC T12, 13 Extract Filter dP Contacts NC T10, 11
24Vac 0V
IO Damper Relay
400V 3ph 50Hz
Main Power Supply
Overcurrent
Protection
(By Others)
Local Rotary Lockable IP66/67 Isolator
L1
E
L2 L3 N
L1 L2 L3 N
T1 T2 T3 N
1 2 3 4
Condensate Pump
Fault Contacts NC
Condensate
Pump Fuse 1A
Internal interconnections are not shown for clarity.
Key:
Factory Connection
Customer Connection (Mandatory)
Customer Connection (Optional)
LPHW Air Off
Set Point Adjust
LPHW Control Board
Valve not supplied as standard
24Vac LPHW Valve Open
24Vac LPHW Valve Close
0V COM
27 Unit Sizes 15 - 20 with LPHW Heating Wiring Diagram

15
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
7.8.4 Unit Sizes 05 - 10 with Electric Heating
28 Unit Sizes 05 - 10 with Electric Heating Wiring Diagram

16
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
7.8.5 Unit Sizes 15 - 20 with Electric Heating
29 Unit Sizes 15 - 20 with Electric Heating Wiring Diagram

17
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
8.0 FROST COIL INSTALLATION (OPTIONAL
ANCILLARY)
8.1 LPHW Frost Coil
LPHW frost coils are fitted with a frost stat on the air in side. Units are
NOT provided with valve and actuator. If the frosts stat switches to
a frost condition, to signal will be sent to open the valve actuator (by
others). The valve will open whether the fans are running or not. This is
for pipe freeze protection. The LPHW section requires its own supply in
order to power the valve actuator.
8.2 Wiring - LPHW Frost Coil Unit Sizes 05 - 20
External
Rotary
Isolator
N L1
LPHW Frost Heater Supply
(Overcurrent protection by others) Recommended Frost
Temperature Setting 4°C
Heater Temperature
Setting
°C
-8
-2 2
8
30 Wiring - LPHW Frost Coil 05 - 20
8.3 Electric Heater Frost Coil
Electric heater frost coils are fitted with its own internal control panel.
The control is powered by a 400Vac 50Hz 3 phase & Neutral supply.
This must be isolated local to the unit and fitted with appropriate
overcurrent and fault protection. It connects to the main unit via
“plug and play” interconnecting looms (see Section 6.4). No external
connections are required. Electric heater elements are protected by
a fail-safe over-temperature switch which will disconnect the heater
supply if a temperature of 80°C is reached. Once the elements cool, the
switch will reset but a power cycle is required to reset the heater supply
contactor.
The frost coil is fitted with a burst fired controller with integral set
point, air off thermistor, air in frost stat, thermal cut-out and contactor.
The burst fired controller is only enabled if the frost stat reads a frost
condition, the over-temperature cut-out is healthy AND a 24vac fan
run signal is received from the main control panel. Once enabled the
burst fired controller will increase heating output to achieve the set
point set by the physical dial on the unit.
8.4 Wiring - Electric Heater Frost Coil Unit Sizes 05 - 20
External
Rotary
Isolator
N L1
Electric Heater
Power Supply
L2 L3
Recommended Frost
Temperature Setting 4°C
Heater Temperature
Setting
°C
-8
-2 2
8
31 Wiring - Electric Frost Coil 05 - 20
8.5 Electrical Supply FLC’s
Unit Size Electric Frost Heater
FLC (Anciliary)
LPHW Frost Coil FLC
(Anciliary)
B*05H/**ES 17.5 A 0.1 A
B*10H/**ES 35 A 0.1 A
B*15H/**ES 52.5 A 0.1 A
B*20H/**ES 52.5 A 0.1 A

18
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
9.0 CONTROLS
9.1 Test Button
The test button allows the individual blowers within the unit to be
checked for its operation. If the fan is running already, press the button
once to stop the fan, press again to switch on the fan. The fan will
return to normal operation after 30 seconds.
9.2 LED Indication
PWR GREEN: Power on & OK.
Standby LED on when fan is not running.
Fan 1 GREEN: Fan 1 is running. RED: Fan 1 faulty.
Fan 2 GREEN: Fan 2 is running. RED: Fan 2 faulty.
Heating* GREEN: Heating selected. RED: Heating faulty.
Cooling* Not applicable, see note.
Fault LED on when a fault is present on unit.
Frost* Not applicable, see note.
TX LED on when the controller is transmitting data.
RX LED on when the controller is receiving data.
*Control panel is common to all Ecosmart products and will have
indicators for functions that are not available in this particular unit.
However these indicators will not be illuminated.
9.3 BMS Input Signals
The system’s response to a 0-10V dc BMS signal is given in the
following table.
The BMS signal will override any sensors and user control connected in
the system. The voltage tolerance is +/- 125mV and is measured at the
fans terminal.
Ventilation Cooling mode* Heating mode*
Local Control 0.00 - -
Off / Trickle 0.25 - -
Speed 1 0.50 0.75 1.00
Speed 2 1.50 1.75 2.00
Speed 3 2.50 2.75 3.00
Speed 4 3.50 3.75 4.00
Speed 5 4.50 4.75 5.00
Speed 6 5.50 5.75 6.00
Speed 7 6.50 6.75 7.00
Speed 8 7.50 7.75 8.00
Speed 9 8.50 8.75 9.00
Speed 10 9.50 9.75 10.00
*Only available on relevant units.
LED Indicators
Min
Min = Minimum Speed
Adjustment
Max = Maximum Speed
Adjustment
SL run on = Switched Live Run-On
Timer Adjustment
Trickle = Selects Trickle Running:
0 = Off,
1 = Selected
Test = Test Button
Max SL run on
Trickle Test
0 1
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
TX
RX
Connector
Ecosmart
32 Ecosmart Commissioning Board
9.4 Settings
9.4.1 Maximum Airflow
•Ensure the power supply is switched off and that a link wire is
connected from the supply L to the SL terminal.
Unplug all items connected to the ‘Net‘ connectors.
•Switch on the power supply.
•Wait for the fan to complete its self-test operation.
Measure the airflow using standard commissioning instruments at a
suitable point in the ductwork. If adjustment is required, rotate the pot
marked ‘Max’ to obtain the desired airflow.
9.4.2 Maximum Trickle Airflow
•Repeat the same procedure as for maximum airflow above but
without the link wire between supply L and SL terminal. Ensure the
trickle switch is in the ‘ON’ position. Adjustment must be made on
the pot marked ‘Min’.
•The minimum setting (nominally 40%) must be below
the maximum setting, otherwise minimum setting will be
automatically set to be the same as the maximum.
9.4.3 Run On Time
A switched live of 100-230V at terminal SL will activate the fan. When
the switched live signal is removed the fan will overrun for period set
by the dial ‘SL run on’ - adjust the desired overrun time by rotating
clockwise.
9.4.4 Trickle Ventilation Facility
Slide the ‘trickle’ switch 0 = Off, 1 = On. With ’trickle’ on and power
to unit the fan will run at minimum speed until the switch live signal
activates it to boost.
9.4.5 Air Off Temperature
The adjustment knob is located in the control pack and must be set to
the desired ‘air off’ temperature.
9.5 Frost Protection
Ecosmart frost protection is activated on any AHU fitted with LPHW
heating, when the outlet air temperature is 4ºC or below.
The unit reacts by shutting down the fan to prevent a ‘wind chill’ effect
reducing the temperature to a point whereby the coil could freeze
and burst. The unit will also drive open the LPHW valve to a fully open
position to allow full water flow through the coil and the main PCB
will close the ‘Heat demand’ contacts. These contacts could be used to
send a signal to activate the boiler and/or valve to open to provide heat
if not already doing so.

19
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
11.0 MAINTENANCE
It is important that maintenance checks are recorded and that the
schedule is always adhered to, in all cases, the previous report should
be referred to.
Motors are fitted with ‘sealed for life’ bearings and do not require any
lubrication. All dampers should be rotated and lubricated as necessary.
11.1 Fans
Please refer to general arrangement drawings for details of the type
of fan and drive that is fitted. Maintenance guidelines for all fans are
beyond this manual, please contact Nuaire for specific documents.
•Before any work is carried out, please ensure that:
•The power supply to the motor is switched off.
•The fan impeller is at rest.
Measures are taken to ensure that the accidental, uncontrolled running
of the fan is prevented during maintenance work.
In general, fans should be inspected twice a year, and care should be
taken to ensure that any unusual vibration or sound is investigated as
an urgent matter.
Access to the fan section is via hinged or lift-off panels. Cable entry
must be made through the apertures provided. Screwed glands with
cable restraint devices should be used.
11.2 General Fan Maintenance
Access to the fan is normally gained by opening the hinged access
doors.
Care should be taken to remove any build up of dust (a light vacuum or
light brushing will normally take care of this) Do not use a steam or any
other high pressure cleaners.
Inspect the connection between the fan and unit for any damage or
wear and tear.
11.3 Bearings
The bearings that are fitted will be (unless otherwise specified) “sealed
for life”, therefore consequence maintenance is not required.
Fan bearings are lifelong; up to 40,000 hours of operation. In cases of
heavy duty operation, maintenance intervals are to be established by
the operator.
11.4 Filters
When removing the filter access panels, pay attention to the airflow
direction marked on the panel, this must be replaced to the exact
position prior to being removed. Disposable filters should be checked,
and changed when they become fully laden with dust. Washable filters
should be removed and washed in a mild detergent, flushed with clean
water and allowed to dry before refitting.
10.0 COMMISSIONING
Before commissioning the unit, ensure that all equipment has been
assembled in accordance with the installation procedure all instances
where the unit is in operation the access doors should remain closed; at
no time, during maintenance or otherwise, should anyone be inside a
unit whilst it is in operation.
10.1 Fan & Motor
Care should be taken to ensure that the fan and motor run freely and
that the fan is rotating in the correct direction.
The electrical current being drawn by motors should not exceed the
manufacturers recommendations (specified on the motor plate). If
the current exceeds this, check the fan volume flow rate and the static
resistance.
10.2 Commissioning Checklist
•All equipment received is according to specification/order.
•Any damage to unit identified.
•Fan base shipping restraints / Fixing Brace removed (if applicable).
•The correct installation procedure has been carried out in
accordance to Nuaire’s recommendations.
•Any fan and thermal wheel motor pulleys are properly aligned.
•Anti-vibration mounts are adjusted accordingly.
•Check / adjust fan and thermal wheel belt tension.
•Rotate fan impellers and motors to ensure they run freely.
•Check any additional bearings and couplings (where fitted
manually).
•Condensate drain traps are checked. Check all filters are correctly
fitted.
•Ensure ductwork is complete.
•Check electrical supply voltage and tightness of all electrical
connections.
•Ensure control damper operation.
•Ensure access panels and doors are fitted properly and secure.
•Check fan motor current draw.

20
26. 08. 21. Document Number 671827
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BPS H-ES
Installation Manual
11.5 Coils
Coils should be connected to ensure that full counter flow exists i.e. the
entering airflow meets the return connection.
All 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 pipe-work
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
techniques, and must be independently supported. The connections
should be pressure tested.
All coils sit in a common drip tray connected to the pre-fitted
condensate pump.
The coil panel has been pre-drilled and fitted with appropriate
grommets for pipe connections. Do not drill or cut the unit casing for
this purpose.
Coils should have their finned surface examined for accumulation of
dirt, lint and biological contaminants or similar. If necessary, wash
down affected areas with a mild detergent solution and a soft brush.
Care should be taken not to damage the finned surface, and any
cleaning fluids should be rinsed away with water.
A compressed air line may be used to blow out any solids between
fins. Do not probe the coil fin block with metal objects as damage
may cause leaks. Drain lines should be checked to ensure that they
are unobstructed and free draining. Drain pans should be flushed out
periodically to remove contamination.
The unit application may require particular attention to this item –
Check with Building Management personnel for details.
11.6 Plate Heat Exchanger
The recuperator block is normally protected from dust and
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
mild detergent solution for grease deposits.
Solvents, strong alkaline, acidic or any products that may be aggressive
to aluminium or plastics should not be used. Do not use cleaning water
over 50°C.
Drain lines should be checked to ensure that they are unobstructed and
free draining. Traps should be checked that they are fully primed and
functioning.
Drain pans should be flushed out periodically to remove contamination,
and chemical treatments may be used to provide protection between
service visits.
The unit application may require particular attention to this item –
Check with Building Management personnel for details.
11.7 Legionella Check
Legionella risk management should be undertaken by a competent
person appointed by the duty holder in accordance with the latest
edition of the HSE approved code of practice L8 Legionnaires’ disease,
the control of legionella bacteria in water systems. Particular attention
should be given to:
•Cooling coil.
•Thermal Wheel.
•Drain trays.
•Water reservoirs.
11.8 Electric Heaters
An air handling unit would normally require no heater maintenance.
However a periodic check is advised to ensure that the fasteners and
electrical connections are operating correctly.
The electric heater unit is fitted with fail-safe thermal switches (self-
resetting) which will isolate the electric heater supply if a temperature
of 80°C is detected. This action is performed independently of any
controls fitted. Nuaire fitted controls will also stop heating if a fan or
heater failure is detected.
11.9 Bulkhead Lights
Ensure that lights are switched off and isolated before checking or
changing the lamp.
11.10 General
Inspect all internal and external surfaces to check for corrosion or
peeling of painted surfaces.
Thoroughly clean affected areas with a wire brush, apply a coat of zinc
rich primer or similar, and re-touch with suitable finishing paint. Ensure
tightness of all nuts, bolts, and fixings.
Check all components for general condition.
11.11 Specialist Equipment
Contact Nuaire for maintenance of specialised equipment that
would have been specified during design stage. A breakdown of the
component parts can be found on the design specification documents,
additional maintenance literature is available, please contact Nuaire.
This applies to any components not specifically mentioned in this
document.
11.12 Maintenance Schedule
11.12.1 Routine Maintenance
•Clean all areas of unit and treat any areas of corrosion.
•Check all access doors for leakage and if necessary locks should be
adjusted and any replacement gasket materials should be replaced
as required.
•Any drain trays should be cleaned and repaired if necessary.
11.12.2 Every 3 Months
•Check filters and change/clean if required, failure to do so may
impair the performance and energy efficiency of this unit.
•Ensure condensate drains are cleaned clear and that water can
flow freely from unit.
•Check fin coil banks and heat exchangers. If necessary clean with a
soft brush or vacuum. Check for signs of contamination.
11.12.3 Annually
•Thoroughly inspect the unit and its components for corrosion,
acting immediately to treat/restore any damaged areas.
•All electrical terminals within the unit should be tightened.
•Check all earth connections.
•Check control dampers blades.
•Check operation of damper actuators and linkages and adjust as
necessary.
•Coil faces should be inspected and any dust removed.
•Check any thermal wheel belt, motor, bearings, seals and if
necessary clean with a soft brush or vacuum cleaner.