NuAire XBOXER Series Assembly instructions

XBOXER
Run Around Co l
Installation, Operatin and
Maintenance Instructions OPTIONS AVAILABLE
The EMC D rect ve
2004/108/EC
The Low Voltage
d rect ve
2006/95/EC
Th s document refers to the follow ng
Nua re Run Around Co l products:
Please note - project specific variations of these products may be
supplied.
Such products will be identified on the unit ratin plate by the
reference – Qaxxxx.
Generally, the standard product information iven here will apply,
and any additional information necessary for the safe installation,
operation and maintenance of the product will be supplied directly
to the contractor.
Un t overall d mens ons (mm)
Un t Code ABC Duct s ze D x E
R4-RAC-L/N/NC 2800 1600 1600 1540 x 740
R5-RAC-L/N/NC 3200 2000 2000 1940 x 940
R6-RAC-L/N/NC 3800 2600 2600 2540 x 1240
N.B If CW or DX modules are included add 600mm to overall len th.
Nua re L m ted Western Industrial Estate Caerphilly United Kin dom CF83 1NA
T: 029 2085 8400 F: 029 2085 8444 E: [email protected] W: www.nuaire.co.uk
117. 06. 15. Leaflet Number 671424
AHU w th Heat Recovery sect on and d rect dr ve AC motor technology.
Fi ure 2. Model shown: R4/6-RAC-N (No heater). Includes Ecosmart control.Fi ure 1. Model shown: R4/6-RAC-L (LPHW). Includes Ecosmart control.
Fi ure 3. Model shown: R4/6NC-RAC-L (LPHW). No Ecosmart control. Fi ure 4. Model shown: R4/6NC-RAC-N (No heater). No Ecosmart control.
Intake
Dischar e
Supply
Extract
Code descr pt on example
1. = Type/Curve Ref.
2. = Ecosmart control as standard
NC = No control
3. = Run around coil
4. = Unit type
L = LPHW
N = No heater
5. = 2 row coil or 3 = 3 row coil
6. = Optional Weather Roof
R4NC - RAC - L 2 WP
|| | || |
12 3 45 6
A
B
C
D
E
Note: Full len th access is from either side.
1600mm for Run Around Coil maintenance.
800mm for filter access etc.
1600mm -
Run Around Coil
maintenance.
800mm -
filter access etc.

2
Assembly with base frame
Palletised Forklift
Slin s via spreaders fitted to unit with
base frame
Safety f rst! –before commenc ng any work ensure:
• That all appropr ate r sk assesments have been carr ed
out, and the requ red safety measures have been taken
• That you understand the work requ red
• That you are tra ned and competent to carry t out
17. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
Drain to open tundish
- Pressure Drain Pan +Pressure Drain Pan
H
H
1.0 General
The information contained in this document ives details of
operation and maintenance for installers and users of Nuaire
XBOXER Run around coil equipment.
These air handlin units comprise a combination of modular
sections assembled (at works or on site) to suit the application
requirements as specified by the purchaser.
General information re ardin performance and specifications for
the equipment may be obtained from our Technical Literature, and /
or project specific documentation.
2.0 Del very of Equ pment
2.1 Rece pt of equ pment
All equipment is inspected prior to despatch and leaves the factory
in ood condition. Upon receipt of the equipment an inspection
should be made and any dama e indicated on the delivery note.
Particulars of dama e and/or incomplete delivery should be
endorsed by the driver deliverin the oods before offloadin by
the purchaser.
No responsibility will be accepted for dama e sustained durin the
offloadin from the vehicle or on the site thereafter.
All claims for dama e and/or incomplete delivery must be reported
to Nuaire within two days of receipt of the equipment.
2.2 Offload ng and Handl ng from the
del very Veh cle
The units will be delivered in 3 sections (see 3.2). The wei ht of the
unit sections and palletised items is displayed on the unit ratin
plate or on the packa in . Some of the sections have an uneven
wei ht distribution, and this will be indicated by labellin where
appropriate. Ensure that liftin and handlin equipment is
adequately rated.
Offloadin and positionin of the equipment is the responsibility of
the purchaser.
Spreaders should be used when liftin with slin s to avoid dama e
to the casin s. Care must be taken to ensure that slin s are
correctly positioned to avoid crushin and twistin of the unit
castin s.
Where channels and/or support frames are bolted to the underside
of the unit casin , slin s or fork-lift arms should be positioned to
locate in the apertures in the channels. If Liftin Eyes have been
supplied / fitted it is recommended that they are used.
Fi ure 5. Liftin
2.3 Storage
The equipment must be stored in a dry, internal location. Ductwork
connection apertures shall be sealed a ainst the in ress of dust,
water and vermin.
Note that units that are intended for external locations are enerally
not fully weatherproof until their installation, includin ductwork
connections is complete.
If the stora e period is to exceed two months, contact Nuaire for
uidance on the appropriate “mothballin ” procedures.
Do not stack units, modules or components.
3.0 Erect on and Assembly
Units must be installed in accordance with ood industry practice,
upri ht and level on a prepared base (which may include a suitably
desi ned suspended platform).
Support positions should be determined to provide a distributed
support for the unit base, and should not obstruct access panels
or air way connections.
Heat recovery modules and modules that incorporate coolin coils
may produce condensation durin use. An insulated drip tray and
drain connection is provided, and should be connected to a suitable
draina e point. (*Note that prov s on of a powered condensate
pump s an opt on for th s type of equ pment. If such a pump s
suppl ed, the ma n dr p tray dra nage po nt should be capped,
and the pump d scharge tube routed as requ red. Spec f c
nstruct ons for the pump type f tted w ll be attached to the
un t.)
Provision may be required, and if so, should be made, for the fittin
of a correctly sized cleanable trap to each drain connection.
Fi ure 6. Draina e point
H (mm) = (Stat c Pressure (Pa) / 10 + 12
The installation, includin all external services and controls should
be installed in accordance with the appropriate authority and
MUST conform to all overnin re ulations e. . CDM,CIBSE, IEE,
and in strict accordance with the applicable Buildin Re ulations.
3.1 Equ pment Access
Access for maintenance and inspection of the XBOXER units is
enerally from the sides of the unit.
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 arran ed
units XBV) be allowed. Guidance may be found in Approved
Document F 2006.

317. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
Isolat on - Before commenc ng work make sure
that the un t and Nua re control are electr cally
solated from the ma ns supply.
1
2
3
Use nuts and studs
to join plates of
facin sections.
Unit base frame.
Slot Fishplate into ends of
base frames and bolt to ether.
Fi ure 9. Installed weatherproof roof components.
3.2 Assembly of Equ pment
SQURBO XBOX unit sections will be delivered to site in 3 sections
shown below.
The sections consist of:
1. Extract Fan sect on,
2. Run Around Co l sect on,
3. Supply Fan sect on ( ncludes heater f spec f ed).
Each Section will be labelled with the direction of air flow. The
d rect on convent on must be observed dur ng assembly. The
un ts may only be operated n the r ntended nstallat on plane.
Fi ure 7. Unit sections shown without weatherproof roof.
Sectional units are supplied with matchin internal connection
plates with a sin le bolt hole provided to each corner throu h
which the sections are bolted to ether. 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.
A sealin asket should be applied as necessary to the matin
faces of the unit frames before boltin to ether.
Fi ure 8. Section assembly plate.
Weatherproof units (see fi ure 9) in multiple sections will have
sectional roof components that must be fitted and sealed after
the unit sections are bolted to ether.
All necessary self drillin screws and sealant are supplied with
each unit and are normally ba ed and located within the fan
section.
The equipment must not be exposed to the weather in an
un-assembled or partially assembled state.
All ductwork, sealin and assembly work must be completed before
the unit can be considered weather-proof.
Pipe-work connections to heatin and / or coolin coils shall be
made to the appropriate standard, and the entire circuit tested for
ti htness. Care must be taken not to over-ti hten and distort
connections to coils.
LPHW Heat ng Co l Flow and Return Connect on s ze
(Standard Co l)
R4-RAC 2 row as standard = 54mm
R5-RAC 3 row as standard = 67mm
R5-RAC 2 row as standard = 67mm
Connection sizes for other coil types are project specific.
Coils are tested durin manufacture to 16
Bar (usin dry compressed air). Operation
of standard equipment is rated at PN6, if
the intended system requires hi her
operatin pressures; please contact the
Nuaire Technical department for advice.
Electrical connections to the unit shall be
made in accordance with the appropriate
product (see below); and installation
wirin dia rams, and shall use appropriately
sized and rated cables.
The unit ratin label shows the maximum
electrical load of the equipment.
Connections to the unit may include three
phase and sin le phase supply connections,
and a variety of control circuits.
Control circuit connections must be
se re ated (i.e. routed separately) from
power connections.
Only the prepared apertures in the unit casin may be used for
cable entry. Do not drill or cut the unit casin for this purpose.
The equipment must be earthed and earth-bonded.
Means of local isolation for maintenance purposes are enerally
required.

4
4.0 W r ng
Wr ng for un ts w thout Ecosmart Control
R4, 5, and 6NC RAC
17. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
U1
V1
W1
W2
U2
V2
3 phase for connection to a
STAR /DELTA STARTER (4kW and above)
400V 3 phase 50Hz supply
STAR
L1 - U1
L2 - V1
L3 - W1
Link W2, U2, V2
DELTA
L1 - U1 - W2
L2 - V1 - U2
L3 - W1 - V2
Note:
For all D.O.L. (Direct On Line)
operation or Inverter type Speed Control
wire in DELTA
V
3 phase for DOL STARTING
(4kW and above)
400V 3 phase 50Hz supply
U1
V1
W1
W2
U2
V2
L1
L2
L3
Three Phase Fi ure 10.
* Note: by spec al order. Refers only to Inverters suppl ed by Nua re.
L1 L2 L3
L1 L/L2 N/L3 PE/ W V U
400V 3 phase 50Hz supply
3 Phase only
INVERTER SPEED CONTROL
Connections
to motor
3 Phase input
Motor
3 phase
Notes:
Total length of motor leads should not exceed 50 metres.
If a screened motor cable is used, maximum length should
be 25 metres. Consult our Technical Department if you
wish to use longer leads.
Inverters are configured to suit specific fans and control
applications as described on the Customer Order
free of charge.
*Matched Frequency Inverter
V

517. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
W r ng for un ts w th Ecosmart Control R4, 5, and 6-RAC ‘N’ (No heater) Extract Fi ure 11.
W r ng for un ts w th Ecosmart Control R4, 5, and 6-RAC ‘N’ (No heater) Supply Fi ure 12.
FAUL RUN
N
L
SL
DP
CL
N
RET
Removethis link wire if:
1. a switchedlivesignal is connected.
2.AES-PIR,ES-TCor BMS signal
is connected.
Min Max SL run on
Trickle Test
01
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Ecosmart
DAMPER
L1 L2 L3 E
(U) (V) (W)
L3
L2
L1
12 13 14 15
5 6 7 8 9 10 11
12 13 14 15
0V
0-10V
BMS signal
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
Net connection
Note: internal connections between thesupplyterminals,
outputcontactors thePCBand inverter are madeatthefactory.
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
W1 V1 U1
W2 V2 U2
Fan 1 Fan 2
W1 V1 U1
W2 V2 U2
Motors 4kW and above
L3
NL2
L1
L3
NL2
L1
Mains supply connections
400V 3 phase 50 Hz + Neutral
FAUL RUN
N
L
SL
DP
CL
N
RET
Removethis link wire if:
1. a switchedlivesignal is connected.
2.AES-PIR, ES-TC or BMS signal
is connected.
Min Max SL run on
Trickle Test
0 1
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Ecosmart
DAMPER
L1 L2 L3 E
(U) (V) (W)
L3
L2
L1
12 13 14 15
5 6 7 8 9 10 11
12 13 14 15
0V
0-10V
BMS signal
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
Net connection
Note: internal connections between thesupplyterminals,
outputcontactors thePCBand inverter are madeatthefactory.
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
W1 V1 U1
W2 V2 U2
Fan 1 Fan 2
W1 V1 U1
W2 V2 U2
Motors 4kW and above
L3
NL2
L1
L3
NL2
L1
Mains supply connections
400V 3 phase 50 Hz + Neutral
Heat
Recovery
Control
Heat
Recovery
Control

617. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
W r ng for un ts w th Ecosmart Control R4, 5, and 6-RAC ‘L’ (LPHW) Extract Fi ure 13.
W r ng for un ts w th Ecosmart Control R4, 5, and 6-RAC ‘L’ (LPHW) Supply Fi ure 14.
FAUL RUN
N
L
SL
DP
CL
N
RET
Removethis link wire if:
1. a switchedlivesignal is connected.
2.AES-PIR,ES-TCor BMS signal
is connected.
Min Max SL run on
Trickle Test
01
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Ecosmart
DAMPER
L1 L2 L3 E
(U) (V) (W)
L3
L2
L1
12 13 14 15
5 6 7 8 9 10 11
12 13 14 15
0V
0-10V
BMS signal
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
Net connection
Note: internal connections between thesupplyterminals,
outputcontactors thePCBand inverter are madeatthefactory.
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
W1 V1 U1
W2 V2 U2
Fan 1 Fan 2
W1 V1 U1
W2 V2 U2
Motors 4kW and above
L3
NL2
L1
L3
NL2
L1
Mains supply connections
400V 3 phase 50 Hz + Neutral
FAUL RUN
N
L
SL
DP
CL
N
RET
Removethis link wire if:
1. a switchedlivesignal is connected.
2.AES-PIR, ES-TC or BMS signal
is connected.
Min Max SL run on
Trickle Test
0 1
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Ecosmart
DAMPER
L1 L2 L3 E
(U) (V) (W)
L3
L2
L1
12 13 14 15
5 6 7 8 9 10 11
12 13 14 15
0V
0-10V
BMS signal
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
Net connection
Note: internal connections between thesupplyterminals,
outputcontactors thePCBand inverter are madeatthefactory.
1 3 5
2 4 6
(U) (V) (W)
CONTACTER
A1
A2
13
14
W1 V1 U1
W2 V2 U2
Fan 1 Fan 2
W1 V1 U1
W2 V2 U2
Motors 4kW and above
L3
NL2
L1
L3
NL2
L1
Mains supply connections
400V 3 phase 50 Hz + Neutral
Heat
Recovery
Control
Heat
Recovery
Control

717. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
W r ng (cont nued)
The electrical wirin must be carried out by a competent person
and the unit must be provided with means of local isolation (by
others) for maintenance purposes.
A suitable isolator is available from Nuaire as a separate option.
Connect ons
a) Ma ns connect ons
Mains cables should be suitably sized and terminated at
terminals shown on the appropriate dia ram.
b) Control connect ons
The facilities described below are provided, but may not be relevant
to your installation – refer to project documentation.
Net - the 4 IDC plu -in connectors are provided for the connection
of compatible sensors, manual controls and for linkin the fans
to ether under a common control. If more than 4 connections are
required, the junction box (product code ES-JB) should be used
(see data cable installation).
c) Sw tched L ve (SL) term nal
A si nal of 100 - 230V a.c. will activate the fan from either its off
state or trickle state (see settin to work-trickle switch).
When the SL is disconnected the fan will over-run (see settin to
work-timer adjustment).
Do not take this si nal from an isolatin transformer.
d) Damper connect ons
OP - 230V 50Hz 1A max supply to open the damper
CL - 230V 50Hz 1A max supply to close the damper
N- Neutral supply to damper
RET - 230V ac return si nal from the damper limit switch
indicates the damper has reached its operatin position.
If the return si nal is not present, the fan will wait for 1 minute
before startin .
Note: If a damper is not fitted, connect a link wire from OP to RET.
This will cancel the delay.
e) Volt Free Relay Contacts
Note that the volt free contacts are not fused. If these are used to
power any external equipment, the installer must provide adequate
fusin or other protection.
These contacts are rated at 5A resistive, 0.5A inductive.
Run connect ons - These contacts are closed when the fan is
runnin .
Fault connect ons - No fault = the contacts are closed.
Fault = the contacts are opened.
Heat demand - contacts closed when heatin is selected.
Cool ng demand - contacts close when coolin selected.
Do not use th s contact to sw tch compressors d rectly.
Frost alarm - contacts close when air off temperature is 40C or
below. Fan shuts down, valve opens and the heat demand contacts
activated.
DX1 - contacts close when sta e 1 of DX coil selected.
DX2 - contacts close when sta e 2 of DX coil selected.
f) Data cable nstallat on
A 4-core SELV data cable is used to connect devices.
Do not run data cable in the same conduit as the mains cables and
ensure there is a 50mm separation between the data cable and
other cables. The maximum cable run between any two devices is
300m when it is installed in accordance with the instructions.
Please note that the total data cable length used n any system
must be less than 1000m. Keep the number of cable jo nts to a
m n mum to ensure the best data transm ss on eff c ency
between dev ces.
g) Max mum number of dev ces
The maximum number of devices (includin fans) that can be
connected to ether via the cable is 32, irrespective of their functions.
h) Other low voltage cables
Keep the cable run as short as possible, less than 50 metres.
j) BMS nput s gnals
The BMS connection is made with a plu -in connector via the
socket (See fi ure 20). To ensure the connection is made only by
suitably qualified and authorised personnel the plu is not
supplied.
It is available from R S Components, Part No. 403-875 or Farnell,
Part No. 963-021.
Reversal of the BMS connect on
w ll damage the control.
Fi ure 15.
‘Net’ connection for
Ecosmart devices.
Fi ure 16.
N
E
L
SL
Remove link if switchedlive signal,
anenabler orBMSsignal is connected
Mains connection
230V 50Hz 1 phase
RUN FAULT
Run signal
Fault signal
C
Fi ure 17a. Drive open/
Sprin close.
Fi ure 18.
All wiring is 1Ph 230V 50Hz
230V
motor
S4
2
S6
1
OP CL N RET
All wiring is 1Ph 230V 50Hz
230V
motor
OP CL N RET
White Brown Blue
A fan starting
delay of 1 minute
is imposed to
enable the damper
to open.
To override the
delay fit a link here
A fan starting
delay of 1 minute
is imposed to
enable the damper
to open.
To override the
delay fit a link here
Fi ure 17b. Drive open/
Drive close.
Cooling
demand
signal
Frost
alarm
signal
Signal for
DX1 coil
if fitted
Signal for
DX2 coil
if fitted
Connect to inlet
sensor after unit
is assembled
Outlet
sensor
Inlet
sensor
Fi ure 19.
Where un ts are suppl ed n modular sect ons, s zes 6 to 10 t w ll
also be necessary to nstall data cable (suppl ed) between Ecosmart
controls and from Ecosmart sensors and heat exchanger etc.
Some anc llary tems (e.g. motor zed dampers, Frost Co ls) may
also requ re ma ns rated and data cable connect ons.
Where un ts form part of a larger system t w ll be necessary to
nstall and connect ma ns w r ng between controls and dev ces
such as heat exchangers and motor sed dampers - refer to the
relevant sect on of th s document.
Where un ts are suppl ed n modular sect ons t w ll also be
necessary to nstall and connect ma ns w r ng
between sensors and actuators and the ma n control locat on.

817. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
W r ng (cont nued)
The system’s response to a 0-10V dc BMS si nal
is iven in the table below.
Note the BMS si nal will override any sensors
and user control connected in the system. The
volta e tolerance is +/_ 125mV and is measured
at the fan’s terminal.
Vent lat on mode Cool ng mode* Heat ng 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 ava lable on relevant un t.
5.0 Comm ss on ng & Sett ng to work
(Note – not all of the components l sted here are necessar ly
ncluded w th the equ pment suppl ed).
5.1 Dampers (shut-off, solat on and
face/bypass)
Check the free action of the damper blades before powered
operation (the actuator has a ear release button).
Check that the actuator operates freely and over the correct ran e.
5.2 M x ng Boxes
Mixin box dampers should be checked as in 4.1 and should be
adjusted / set up to ive the required airflows throu h each le .
5.3 F lters
Remove filter access panels (observe and note airflow direction
labels), inspect filters for contamination with construction debris,
replace as necessary. Replace access panels.
Filter pressure drops will depend on actual flow rate and condition.
Observe and record filter pressure drops after performance
commissionin .
Typically, filter “dirty” condition occurs when the initial filter
“clean” readin s have been increased by 125Pa.
If filter manometers, pressure switches or indicators have been
fitted, they should be set or adjusted to reflect the commissioned
system operation.
5.4 Heat ng & Cool ng Co ls
Water
Water coils should be connected to ensure that full counter flow
exists i.e. - the enterin airflow meets the return connection.
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 pipe-work dependin on the installation.
Frost protection must be incorporated on shut down and fresh air
conditions to avoid coil freezin . The Ecosmart control system if
fitted, includes temperature sensin and frost protection
strate ies. Ideally, where the system is at risk of frost dama e,
the addition of a proprietary anti-freeze solution to the water is
recommended.
Where Ecosmart heatin / coolin controls are provided, the coil
is pre-fitted with a 3 / 4 port valve and actuator housed in the
casin extension.
Pipe-work connections should be made to the unit usin appropriate
techniques, and must be independently supported. The connections
should be pressure tested.
DX
Direct expansion coils must be fitted with a correctly sized
thermostatic expansion valve with an external equalisin connection.
The expansion valve phial must be fitted between the suction
header connection and the equalisin line. The recommendations
of the TE valve manufacturer should be referred to when locatin
the phial and adjustin the superheat. In all cases, settin s should
be in accordance with the recommendations of the manufacturer
of the refri eration equipment.
All coolin coil drains must be connected to the slopin drain with
a correctly sized trap runnin to an open tundish or similar.
Note: ES-TC must be used n conjunct on w th DX.
5.5 Electr c Heaters
Remove control access panel to permit site wirin to the Ecosmart
heatin controller, or directly to the heatin elements.
Elements have threaded connection points for linkin elements
and site wirin . Elements should be linked with reference to the
appropriate wirin dia ram, and the maximum available element
power combination may be decreased if required. Always maintain
a balanced load on three phase systems.
Cable entry must be made throu h the apertures provided.
Screwed lands with cable restraint devices should be used.
PVC or similar cables must not be used inside the heater unit –
due to the temperatures that may be experienced.
Units with Ecosmart electric heatin controls incorporate a fan
run-on facility and overheat / fan failure protection.
In non-Ecosmart units, heaters are fitted with an over-heat cut-out
that must be wired into the control system.
It is stron ly recommended that an airflow switch is incorporated
within the control system with a fan run on timer (15 minutes) and
an interlock provided between the heater contactor and fan motor
starter – to allow elements to cool on shutdown.
Nuaire will accept no liability for dama e caused by an inadequate
control system.
All heaters must be wired in accordance with IEE re ulations and
conform to local and national statutory requirements. The element
tray s a ma ns carry ng component and must be earthed.
5.6 Fan Sect ons
Access to the fan section is via lift off panels. Cable entry must be
made throu h the apertures provided. Screwed lands with cable
restraint devices should be used.
For units with Ecosmart controls, the fan motors and failure
protection devices are pre-wired to the control assembly.
For non-Ecosmart units, wirin to the fan motor / unit terminal
box should be mechanically protected and in made in accordance
with the details on the motor name plate and dia ram attached to
the unit.
For star delta startin , all links should be removed from the motor
terminal box and the motor wired as per the instructions supplied
with starter.
With the unit electrically isolated, rotate the fan impeller / drive
manually, checkin that it spins freely. Check all fixin s are
secure.
Units must not be operated without all access panels in place –
dama e to equipment or injury to personnel may result.
Units must not be operated unless control interlocks are in place –
dama e to equipment may result. Test run motor for condition and
correct rotation.
Check that the correct current overloads are fitted and that the
current bein drawn does not exceed the motor nameplate value.
Excessive current normally indicates that the ductwork system
resistance is different to desi n.
Fi ure 20.
0 - 10V
0V
BMS

9
Isolat on - Before commenc ng work make sure that the un t and
Nua re control are electr cally solated from the ma ns supply.
Warn ng - Inverter Speed Control
An Inverter s used to prov de speed control. When the fan s
solated, allow 5 m nutes for the capac tors n the nverter to
d scharge before commenc ng any work on the un t.
17. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
5.7 Electr cal – Ecosmart Un ts
Comm ss on ng panel - Us ng the Test button
The panel is located within the control enclosure – one for each
fan.
The test button allows the fan within the unit to be checked for
correct operation. If the fan is runnin already, press the button
once to stop the fan, press a ain to switch on the fan.
Note that the fan w ll return to normal operat on after
30 seconds.
LED Ind cat on
PWR GREEN: Power on & OK,
Standby LED on when fan is not runnin .
Fan 1 GREEN: Fan 1 is runnin , RED: Fan 1 faulty.
Fan 2 GREEN: Fan 2 is runnin , RED: Fan 2 faulty.
Heat ng* GREEN: Heatin selected
Cool ng* GREEN: Coolin selected
Fault: LED on when a fault is present on unit.
Frost* RED: Frost condition exists
Tx LED on when the controller is transmittin data.
Rx LED on when the controller is receivin data.
* Note that th s control panel s common to all the Nua re
Ecosmart products and may have nd cators for funct ons
that are not ava lable n nd v dual un ts – however, the unused
nd cators w ll not be llum nated.
5.8 Sett ngs
Sett ng the max mum a r flow
i) Ensure the power supply is switched off and that a linkwire is
connected from the supply L to the SL terminal. Unplu all items
connected to the ‘Net‘ connectors.
ii) Switch on the power supply.
iii) Wait for the fan to complete its self-test operation.
Measure the airflow usin standard commissionin instruments at
a suitable point in the ductwork.
If adjustment is required, rotate the pot marked ‘MAX’ to obtain
the desired airflow. Remove the link wire if not required.
Sett ng the m n mum/tr ckle a rflow rate
(Nom nally 40% for S6 un ts and 20% for all others as
standard).
i) 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’.
ii) Note that the minimum settin (nominally 40%) must be below
the maximum settin , otherwise the minimum settin will be auto-
matically set to be the same as the maximum.
iii) The minimum speed set is the trickle speed at which the fan
operates.
Note: The work ng adjustment of the fan speed by user control
and sensors, ranges between the m n mum and max mum set
po nts.
Note :- Where th rd party controls are spec f ed and f tted, ref-
erence should be made to the control spec f cat on and operat-
ng nstruct ons.
It s the nstaller’s respons b l ty to ensure that such controls
are su table for operat on w th the Nua re equ pment.
Nua re w ll accept no l ab l ty for equ pment damage result ng
from ncompat ble controls.
Mechan cal
i) Wet systems require the settin of the coil bypass balancin
valve, set usin eneral commissionin procedures - refer to the
specified desi n flow duties and any documentation attached to
the valve.
6.0 Ma ntenance
It is recommended that PPE is always used durin the maintenance
of Air Handlin Equipment – loves, eye shields and respiratory
mask.
In some Ecosmart units and in some third party controls, variable
speed drives (inverters) are used to provide fan speed control.
After the fan is isolated, allow at least 5 minutes for the capacitors
in the inverter to dischar e before commencin any work on the
unit.
6.1 Dampers
At re ular intervals check that the blades move freely.
6.2 F lters
Disposable filters should be chan ed when fully dust laden.
Washable filters should be removed when fully dust laden and
washed in mild deter ent, flushed with clean water and allowed to
dry before replacin .
Carbon filters should be replaced once carbon activation is
exhausted.
Inclined au e manometers, where fitted, should be checked for
fluid level.
6.3 Heat ng and Cool ng Co ls
Coils should have their finned surface examined for accumulation
of dirt, lint and biolo ical contaminants or similar. If necessary,
wash down affected areas with a mild deter ent solution and
a soft brush. Care should be taken not to dama e the finned
surface, and any cleanin 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 dama e
may cause leaks.
Drain lines should be checked to ensure that they are unobstructed
and free drainin . Traps should be checked that they are fully
primed and functionin .
Drain pans should be flushed out periodically to remove
contamination.
Note: The un t appl cat on may requ re part cular attent on to
th s tem – Check w th Bu ld ng Management personnel for
deta ls.
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
LED indicators
Min Max SL run on
Trickle Test
0 1
Pwr
Standby
Fan 1
Fan 2
Heating
Cooling
Fault
Frost
Tx
Rx
Ecosmart
Connector
Fi ure 21.

6.4 Electr c Heaters
Electric heaters should be checked at re ular intervals for condition
of elements, wirin and insulation.
6.5 Recuperator
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 sprayin
with a mild deter ent solution for rease deposits. Solvents,
stron alkaline, acidic or any products that may be a ressive to
aluminium should not be used. Do not use cleanin water over 50
de C.
Drain lines should be checked to ensure that they are unobstructed
and free drainin . Traps should be checked that they are fully
primed and functionin .
Drain pans should be flushed out periodically to remove
contamination, and chemical treatments may be used to provide
protection between service visits.
Note: The un t appl cat on may requ re part cular attent on to
th s tem – Check w th Bu ld ng Management personnel for
deta ls.
6.6 Ma ntenance and Clean ng of
Rotat ng Heat Exchangers
Ma ntenance of the rotor
To secure the function and performance, the face of the rotor has to
be inspected re ulary for dust and dirt. Any dirt or/and dust should
be removed. For a small amount of easily removable dirt we
recommend to use a vacuum cleaner. For heavier deposits it is
possible to use compressed air, with caution. Finally, firm dirt in
the rotor can be removed by usin hot water and a mild deter ent.
Ma ntenace of dr ve un t
Tension of the V-belt must be checked after the first 100 hours of
operation to secure the rotational function of the wheel.
To adjust tens on, first check the belt tensioner and adjust it as
much as possible. Secondly, shortenin of the V-belt may be
required. The V-belt is joined to ether by an easily removable
mechanical lock. Ensure adjustment of the belt tens oner after
th s operat on.
The round belt is self tensioned and no adjustment should be needed.
Ma ntenace of brush sealants
Ti htness between brush sealants and casin has to be checked
durin inspection. The brush sealants are easily adjusted by
losenin the screws and movin the brush sealant into the ri ht
position.
V-belt, Round belt and brush sealants are all available as spare
parts.
Check ng dr ve belt tens on
To check the correct tension of a drive belt, apply a force at ri ht
an les to the centre of the belt span sufficient to deflect the belt
16mm for every metre of span len th.
The force required to deflect the ‘V’ belt should be from 0.5k to
0.8k .
Chang ng a dr ve belt
To replace a belt, remove the two bolts from the motor mountin
furthest from the fan and slacken the remainin two bolts. Lift the
motor plate and remove the belt. Replacin the belt is the reverse
of this procedure.
Adjust ng dr ve belt tens on
All belt drive units incorporate a belt tensionin facility.
To adjust the belt tension, slacken the pinch bolts on the sides of
the motor plate. Use the motor platform pivot adjustment to
ti hten and loosen the belt.
Clean impellers with a soft brush only, and remove dust/deposits
from all internal surfaces includin the motor housin ,
6.7 General
Inspect all internal and external surfaces to check for corrosion or
peelin of painted surfaces.
Thorou hly clean affected areas with a wire brush, apply a coat of
zinc rich primer or similar, and re-touch with suitable finishin
paint. Ensure ti htness of all nuts, bolts, and fixin s. Check all
components for eneral condition.
7.0 Serv ce
Serv ce schedule (typ cal – w ll depend on s te
cond t ons)
6 MONTHS 12 MONTHS
FILTERS 4or 4
DAMPERS 4
DAMPER ACTUATORS 4
BELT DRIVES 4
FILTER MANOMETER FLUID 4
VENT WATER COILS 4
COIL FINNED SURFACES 4
CHECK DRAIN LINES + DRIP TRAY 44
CLEAN & FLUSH DRAIN PANS Buildin
Schedule ? 4
NUTS, BOLTS, FIXINGS SECURE 4
FAN BEARINGS 4
ELECTRIC HEATERS 4
ELECTRICAL WIRING 4
FAN IMPELLER 4
GENERAL 4
8.0 Warranty
Ecosmart XBOXER TWB units have a 5 year warranty.
No control units have a 2 year warranty. The first year covers
parts and labour and the remainin period covers parts only.
This warranty is void if the equipment is modified without
authorisation, is incorrectly applied, misused or not installed
commissioned and maintained in accordance with the details
contained in this manual and eneral ood practice.
9.0 Spares
Spare parts and replacement components, and eneral advice are
available from the Technical Support department.
Telephone [phone]
Fax [phone]
10 17. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
Fi ure 22.

11 17. 06. 15. Leaflet Number 671424
DECLARATION OF INCORPORATION AND INFORMATION FOR SAFE INSTALLATION,
OPERATION AND MAINTENANCE
To comply w th EC Counc l D rect ves 2006/42/EC Mach nery D rect ve and
2004/108/EC (EMC).
To be read n conjunct on w th the relevant Product Documentat on (see 2.1)
1.0 GENERAL
1.1 The equipment referred to in this Declarat on of Incorporat on 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 re ard to
current le islation 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 ratin plate attached to its outer casin . The ratin plate
provides essential data relatin 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,
contact Nuaire.
2.3 Where warnin labels or notices are attached to the unit the instructions iven
must be adhered to.
3.0 TRANSPORTATION, HANDLING AND STORAGE
3.1 Care must be taken at all times to prevent dama e to the equipment. Note that
shock to the unit may result in the balance of the impeller bein affected.
3.2 When handlin the equipment, care should be taken with corners and ed es and
that the wei ht distribution within the unit is considered. Liftin ear such as
slin s or ropes must be arran ed so as not to bear on the casin .
3.3 Equipment stored on site prior to installation should be protected from the
weather and steps taken to prevent in ress of contaminants.
4.0 OPERATIONAL LIMITS
4.1 It is important that the specified operational limits for the equipment are
adhered to e. . operational air temperature, air borne contaminants and unit
orientation.
4.2 Where installation accessories are supplied with the specified equipment e .
wall mountin brackets. They are to be used to support the equipment only.
Other system components must have separate provision for support.
4.3 Flan es and connection spi ots are provided for the purpose of joinin to
duct work systems. They must not be used to support the ductwork.
5.0 INSTALLATION REQUIREMENTS
In addition to the particular requirements iven for the individual product, the
followin eneral requirements should be noted.
5.1 Where access to any part of equipment which moves, or can become electr cally
l ve are not prevented by the equipment panels or by fixed installation detail
(e ductin ), then uardin 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 re ulations.
5.3 For EMC all control and sensor cables should not be placed within 50mm or on
the same metal cable tray as 230V switched live, li htin or power cables and
any cables not intended for use with this product.
6.0 COMMISSIONING REQUIREMENTS
6.1 General pre-commissionin checks relevant to safe operation consist of the
followin :
Ensure that no forei n bodies are present within the fan or casin .
Check electrical safety. e. . Insulation and earthin .
Check uardin of system.
Check operation of Isolators/Controls.
Check fastenin s for security.
6.2 Other commissionin requirements are iven in the relevant product documentation.
7.0 OPERATIONAL REQUIREMENTS
7.1 Equipment access panels must be in place at all times durin operation of the
unit, and must be secured with the ori inal fastenin s.
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 ran es of equipment are desi ned to detect and compensate for fan failure).
8.0 MAINTENANCE REQUIREMENTS
8.1 Specific maintenance requirements are iven 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 st ll be taken however s nce a rflow generated at some
other po nt n the system can cause the mpeller to “w ndm ll” even when
power s not present.
8.5 Care should be taken when removin and storin access panels in windy
conditions.
INFORMATION FOR SAFE INSTALLATION, OPERATION AND MAINTENANCE
OF NUAIRE VENTILATION EQUIPMENT
We declare that the mach nery named below s ntended to be
assembled w th other components to const tute a system of
mach nery. The mach nery shall not be put nto serv ce unt l the
system has been declared to be n conform ty w th the prov s ons of the
EC Mach nery D rect ve.
Des gnat on of mach nery: XBOXER-RAC Run Around Coil
Mach nery Types: Heat Recovery
Relevant EC Counc l D rect ves: 2006/42/EC (Machinery Directive)
Appl ed Harmon sed Standards: BS EN ISO 12100-1, BS EN ISO 12100-2,
EN294, EN60204-1, BS EN ISO 9001
Appl ed Nat onal Standards: BS848 Parts One, Two and Five
Note: All standards used were current and valid at the date of si nature.
Sgnature of manufacture representat ves:
Name: Position: Date:
1) C. Bi s Technical Director 20. 07. 07
2) A. Jones Manufacturin Director 20. 07. 07
Technical or commercial considerations may, from time to time, make it necessary to alter the desi n, performance and
dimensions of equipment and the ri ht is reserved to make such chan es without prior notice.

12 17. 06. 15. Leaflet Number 671424
Installation, Operatin and Maintenance Instructions XBOXER Run Around Coil
Western Industrial Estate
Caerphilly United Kin dom
CF83 1NA
T: 029 2085 8400
F: 029 2085 8444
E: [email protected]
W: www.nuaire.co.uk