NuAire XBOXER T1-TWB Series User manual

XBOXER
Thermal Wheel Sizes T1-TWB - T6-TWB
Installation, Operating and
Maintenance Instructions
The EMC Directive
2004/108/EC
The Low Voltage
directive
2006/95/EC
Nuaire Limited Western Industrial Estate Caerphilly United Kingdom CF83 1NA
T: 029 2088 5911 F: 029 2088 7033 E: [email protected] W: www.nuaire.co.uk
1Leaflet Number 671423 October 2010
AHU with Heat Recovery section and direct drive AC motor technology.
Figure 2. Model shown: T1/3-TWB-DX (with DX coil) Includes Ecosmart control.Figure 1. Model shown: T1/3-TWB-L (LPHW). No Ecosmart control.
Figure 3. Model shown: T4/6NC-TWB-L (LPHW). No Ecosmart control. Figure 4. Model shown: T4/6NC-TWB-N (No heater). No Ecosmart control.
Code description example
1. = Type/Curve Ref.
2. = Ecosmart control as standard
NC = No control
3. = Thermal wheel box
4. = Unit type
L = LPHW
N = No heater
5. = 2 row coil or 3 = 3 row coil
6. = Optional Weather Roof
T4NC - TWB - L 2 WP
|| | || |
12 3 45 6
A
B
C
D
E
Note: Full length access is from either side.
1600mm for Thermal Wheel maintenance.
800mm for filter access etc.
1600mm -
Thermal Wheel
maintenance.
800mm -
filter access etc.
This document refers to the following
Nuaire Thermal Wheel products:
Please note - project specific variations of these products may be
supplied.
Such products will be identified on the unit rating plate by the
reference – Qaxxxx.
Generally, the standard product information given 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.
Unit overall dimensions (mm)
Unit Code A B C Duct size D x E
T1-TWB-** 1270 1070 1163 740 X 395
T2-TWB-** 1470 1070 1163 949 X 494
T3-TWB-** 2575 1200 1676 1440 X 740
T4-TWB-** 2800 1600 1600 1540 X 740
T5-TWB-** 3200 2000 2000 1940 X 940
T6-TWB-** 3800 2600 2600 2540 X 1240
N.B If CW or DX modules are included add 600mm to overall length.
Supply
Extract Exhaust
Intake

2
Assembly with base frame.
Palletised. Forklift.
Slings via spreaders fitted to unit with
base frame.
Safety first! –before commencing any work ensure:
• That all appropriate risk assesments have been carried
out, and the required safety measures have been taken
• That you understand the work required
• That you are trained and competent to carry it out
Leaflet Number 671423 October 2010
Drain to open tundish
- Pressure Drain Pan +Pressure Drain Pan
H
H
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
1.0 General
The information contained in this document gives details of
operation and maintenance for installers and users of Nuaire
XBOXER Thermal Wheel equipment.
These air handling 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 regarding performance and specifications for
the equipment may be obtained from our Technical Literature, and /
or project specific documentation.
2.0 Delivery of Equipment
2.1 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.
2.2 Offloading and Handling from the
delivery Vehicle
Units (size 1 - 3) will be delivered to site in 1 piece. Units (size 4 - 6)
will be delivered to site in 3 sections (see section 3.2). Palletised
items are displayed on the unit rating plate or on the packaging.
Some of the sections have an uneven weight distribution, and this
will be indicated by labelling where appropriate. Ensure that lifting
and handling equipment is adequately rated.
Offloading and positioning of the equipment is the responsibility of
the purchaser.
Spreaders should be used when lifting with slings to avoid damage
to the casings. Care must be taken to ensure that slings are
correctly positioned to avoid crushing and twisting of the unit
castings.
Where channels and/or support frames are bolted to the underside
of the unit casing, slings or fork-lift arms should be positioned to
locate in the apertures in the channels. If Lifting Eyes have been
supplied / fitted it is recommended that they are used.
Figure 5. Lifting.
2.3 Storage
The equipment must be stored in a dry, internal location. Ductwork
connection apertures shall be sealed against the ingress of dust,
water and vermin.
Note that units that are intended for external locations are generally
not fully weatherproof 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.
3.0 Erection and Assembly
Units must be installed in accordance with good industry practice,
upright and level on a prepared base (which may include a suitably
designed 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 cooling coils
may produce condensation during use. An insulated drip tray and
drain connection is provided, and should be connected to a suitable
drainage point. (*Note that provision of a powered condensate
pump is an option for this type of equipment. If such a pump is
supplied, the main drip tray drainage point should be capped,
and the pump discharge tube routed as required.
Specific instructions for the pump type fitted will be attached
to the unit.)
Provision may be required, and if so, should be made, for the fitting
of a correctly sized cleanable trap to each drain connection.
Figure 6. Drainage point.
H (mm) = (Static Pressure (Pa) / 10 + 12
The installation, including all external services and controls should
be installed in accordance with the appropriate authority and
MUST conform to all governing regulations e.g. CDM,CIBSE, IEE,
and in strict accordance with the applicable Building Regulations.
3.1 Equipment Access
Access for maintenance and inspection of the XBOXER units is
generally 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.
Note: Full length access is from either side. 1600mm for Thermal
Wheel maintenance and 800mm for filter access etc..
Guidance may be found in Approved Document F 2006.

3Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
Isolation - Before commencing work make sure
that the unit and Nuaire control are electrically
isolated from the mains supply.
1
2
3
Use nuts and studs
to join plates of
facing sections.
Unit base frame.
Slot Fishplate into ends of
base frames and bolt together.
Figure 9. Installed weatherproof roof components.
3.2 Assembly of Equipment
XBOXER Thermal wheel units (size 1 - 3) will be delivered to site in
1 piece. Units (size 4 - 6) will be delivered to site in 3 sections.
The sections for units 4 - 6 consist of:
1. Extract Fan section,
2. Thermal Wheel section,
3. Supply Fan section (includes heater if specified).
Each Section will be labelled with the direction of air flow. The
direction convention must be observed during assembly. The
units may only be operated in their intended installation plane.
Figure 7. Unit sections size 4 - 6 shown without weatherproof roof and
ready for on-site assembly.
Sectional units are supplied with matching internal connection
plates with a single bolt hole provided to each corner through
which the sections are bolted together. Unit access panels must be
removed to perform the assembly operation plates will either have
clearance holes - or one face with a threaded insert and the other
with a clearance hole.
A sealing gasket should be applied as necessary to the mating
faces of the unit frames before bolting together.
Figure 8. Section assembly plate.
Weatherproof units (see figure 9) in multiple sections will have
sectional roof components that must be fitted and sealed after
the unit sections are bolted together.
All necessary self drilling screws and sealant are supplied with
each unit and are normally bagged 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, sealing and assembly work must be completed before
the unit can be considered weather-proof.
Pipe-work connections to heating and / or cooling coils shall be
made to the appropriate standard, and the entire circuit tested for
tightness. Care must be taken not to over-tighten and distort
connections to coils.
LPHW Heating Coil Flow and Return Connection size
(Standard Coil)
T1-TWB 2 row as standard = 22mm
T2-TWB 2 row as standard = 22mm
T3-TWB 2 row as standard = 35mm
T4-TWB 2 row as standard = 54mm
T5-TWB 3 row as standard = 67mm
T6-TWB 2 row as standard = 67mm
Connection sizes for other coil types are project specific.
Coils are tested during manufacture to 16 Bar
(using dry compressed air). Operation of
standard equipment is rated at PN6, if the
intended system requires higher operating
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 wiring diagrams, and
shall use appropriately sized and rated cables.
The unit rating label shows the maximum
electrical load of the equipment.
Connections to the unit may include three phase
and single phase supply connections, and a
variety of control circuits.
Control circuit connections must be segregated
(i.e. routed separately) from power connections.
Only the prepared apertures in the unit casing may be used for
cable entry. Do not drill or cut the unit casing for this purpose.
The equipment must be earthed and earth-bonded.
Means of local isolation for maintenance purposes are generally
required.

4.0 Control Unit for Rotating Heat
Exchangers
Functional description
Micromax - enclosed IP54, is a modern frequency converter with
the additional functions which are necessary to control a rotating
heat exchanger optimally. Input signal 0 - 10V.
The number of revolutions of the heat exchanger and in
consequence its efficiency, is regulated by the control unit so that
the number of revolutions of the rotor is proportional to the imput
signal from the control central.
Other Operational Functions
a) Purification
The heat exchanger rotates at minimum speed for 10 seconds every
30 minutes if the input signal is below the threshhold value (e.g.
the rotor does not move).
The function can be disconnected via a DIP change-over switch.
b) Rotation monitor
The rotation monitor (a magnet installed on the rotor with the
magnetic transducer) stops the converter and sounds the alarm at
if the belt breaks or similar. The control unit is released if a pulse is
not received every 5 minutes.
The function can be disconnected via a DIP change-over switch.
c) Threshold value
The control unit has a prset threshold value of 0.1V, if the input
signal is below this value, the rotor stops.
d) Resetting
Via a reset button, alternatively a voltage drop.
e) Restart
Automatic restart after a voltage drop.
f) Separation
Separation between engine and control must not take place when
loaded.
4.1 General data
4.2 Connections
a) Thermojunction (T-T)
Must be looped if the thermojunction of the engine is not
connected.
b) Alarm relay (13-14-15)
Closes between 14 - 15 at alarm or voltage drop. Max 8A/250V AC.
c) Input signal (2-3)
0 - 10V.
d) Rotation monitor (9-10)
White cable is connected to terminal block 9, brown cable to
terminal block 10. The magnet is installed with the south side
towards the transducer. Max distance 15mm.
4.3 Manual driving (at test)
a) At high speed
The engine rotates at preset maximum revolutions when the DIP
switch is in the position ‘on’.
b) At low speed
The engine rotates at preset minimum revolutions when the DIP
switch is in the position ‘on’.
4Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
Motor performance 90 W Acceleration time (Fixed) 30 s
max
Motor current max. 1.0 A Retardation time (Fixed) 30 s
Overload 2min/30min 1.3 A Ambient temp.
Connection voltage 1x230 +6-10% V not condensing 0-45 0C
Connection frequency 50-60 Hz Protection form IP54
Output voltage 3x0-230 V Weight 0.9 kg
Output frequency 4-100 Hz Measures hxbxd 158x164x60 mm
Min frequency (Fixed) 4 Hz Internal fuse 2 AT
Max frequency 40-100 Hz Incoming fuse max 10 A
Control terminal block
2 3 9 10
(Max 5A / 250V AC)
U V W T T
13 14 15
M
3~
S
w b
Output
3 x 230V
Input
thermal
contact
Output
alarm
relay
+ -
Input
signal
0 - 10V
Input
rotation
monitor
Heat
Recovery
Control
Heat
Recovery
Control
L N
Input
1 x 230V
Figure 10. Connections.

5
4.0 Wiring
Wiring for units without Ecosmart Control
T4, 5 and 6NC TWB
Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
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
3 phase for DOL STARTING
(4kW and above)
400V 3 phase 50Hz supply
U1
V1
W1
W2
U2
V2
L1
L2
L3
Three Phase Figure 11.
* Note: by special order. Refers only to Inverters supplied by Nuaire.
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

6Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
Wiring for units with Ecosmart Control T1. 2. 3. 4, 5 and 6-TWB ‘N’ (No heater) Extract Figure 12.
Wiring for units with Ecosmart Control T1. 2. 3. 4, 5 and 6-TWB ‘N’ (No heater) Supply Figure 13.
FAUL RUN
N
L
SL
DP
CL
N
RET
Remove this link wire if:
1. a switched live signal is connected.
2. A ES-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 the supply terminals,
output contactors the PCB and inverter are made at the factory.
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
Remove this link wire if:
1. a switched live signal is connected.
2. A ES-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 the supply terminals,
output contactors the PCB and inverter are made at the factory.
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

7Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
Wiring for units with Ecosmart Control T1. 2. 3. 4, 5 and 6-TWB ‘L’ (LPHW) Extract Figure 14.
Wiring for units with Ecosmart Control T1. 2. 3. 4, 5 and 6-TWB ‘L’ (LPHW) Supply Figure 15.
FAUL RUN
N
L
SL
DP
CL
N
RET
Remove this link wire if:
1. a switched live signal is connected.
2. A ES-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 the supply terminals,
output contactors the PCB and inverter are made at the factory.
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
Remove this link wire if:
1. a switched live signal is connected.
2. A ES-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 the supply terminals,
output contactors the PCB and inverter are made at the factory.
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

8Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
Wiring (continued)
The electrical wiring 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.
Connections
a) Mains connections
Mains cables should be suitably sized and terminated at
terminals shown on the appropriate diagram.
b) Control connections
The facilities described below are provided, but may not be relevant
to your installation – refer to project documentation.
Net - the 4 IDC plug-in connectors are provided for the connection
of compatible sensors, manual controls and for linking the fans
together 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) Switched Live (SL) terminal
A signal of 100 - 230V a.c. will activate the fan from either its off
state or trickle state (see setting to work-trickle switch).
When the SL is disconnected the fan will over-run (see setting to
work-timer adjustment).
Do not take this signal from an isolating transformer.
d) Damper connections
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 signal from the damper limit switch
indicates the damper has reached its operating position.
If the return signal is not present, the fan will wait for 1 minute
before starting.
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
fusing or other protection.
These contacts are rated at 5A resistive, 0.5A inductive.
Run connections - These contacts are closed when the fan is
running.
Fault connections - No fault = the contacts are closed.
Fault = the contacts are opened.
Heat demand - contacts closed when heating is selected.
Cooling demand - contacts close when cooling selected.
Do not use this contact to switch compressors directly.
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 stage 1 of DX coil selected.
DX2 - contacts close when stage 2 of DX coil selected.
f) Data cable installation
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 in any system
must be less than 1000m. Keep the number of cable joints to a
minimum to ensure the best data transmission efficiency
between devices.
g) Maximum number of devices
The maximum number of devices (including fans) that can be
connected together 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 input signals
The BMS connection is made with a plug-in connector via the
socket (See figure 21). To ensure the connection is made only by
suitably qualified and authorised personnel the plug is not
supplied.
It is available from R S Components, Part No. 403-875 or Farnell,
Part No. 963-021.
Reversal of the BMS connection
will damage the control.
Figure 16.
‘Net’ connection for
Ecosmart devices.
Figure 17.
N
E
L
SL
DP
CL
N
RET
DAMPER D
Remove link if switched live signal,
an enabler or BMS signal is connected
Damper connection
Heat demand signal
Mains connection
230V 50Hz 1 phase
RUN FAULT
Run signal
Fault signal
Figure 18a: Drive open/
Spring close.
Figure 19.
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
Figure 18b: 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
Figure 20.
Where units are supplied in modular sections, sizes 6 to 10 it will
also be necessary to install data cable (supplied) between Ecosmart
controls and from Ecosmart sensors and heat exchanger etc.
Some ancillary items (e.g. motorized dampers, Frost Coils) may
also require mains rated and data cable connections.
Where units form part of a larger system it will be necessary to
install and connect mains wiring between controls and devices
such as heat exchangers and motorised dampers - refer to the
relevant section of this document.
Where units are supplied in modular sections it will also be
necessary to install and connect mains wiring
between sensors and actuators and the main control location.

9Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
Wiring (continued)
The system’s response to a 0-10V dc BMS signal
is given in the table below.
Note the BMS signal will override any sensors
and user control connected in the system. The
voltage tolerance is +/_ 125mV and is measured
at the fan’s terminal.
Ventilation mode 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 unit.
5.0 Commissioning & Setting to work
(Note – not all of the components listed here are necessarily
included with the equipment supplied).
5.1 Dampers (shut-off, isolation and
face/bypass)
Check the free action of the damper blades before powered
operation (the actuator has a gear release button).
Check that the actuator operates freely and over the correct range.
5.2 Mixing Boxes
Mixing box dampers should be checked as in 4.1 and should be
adjusted / set up to give the required airflows through each leg.
5.3 Filters
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
commissioning.
Typically, filter “dirty” condition occurs when the initial filter
“clean” readings 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 Heating & Cooling Coils
Water
Water coils should be connected to ensure that full counter flow
exists i.e. - the entering 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 depending on the installation.
Frost protection must be incorporated on shut down and fresh air
conditions to avoid coil freezing. The Ecosmart control system if
fitted, includes temperature sensing and frost protection
strategies.
Ideally, where the system is at risk of frost damage, the addition
of a proprietary anti-freeze solution to the water is recommended.
Where Ecosmart heating / cooling controls are provided, the coil
is pre-fitted with a 3 / 4 port valve and actuator housed in the
casing extension.
Pipe-work connections should be made to the unit using 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 equalising connection.
The expansion valve phial must be fitted between the suction
header connection and the equalising line. The recommendations
of the TE valve manufacturer should be referred to when locating
the phial and adjusting the superheat. In all cases, settings should
be in accordance with the recommendations of the manufacturer
of the refrigeration equipment.
All cooling coil drains must be connected to the sloping drain with
a correctly sized trap running to an open tundish or similar.
Note: ES-TC must be used in conjunction with DX.
5.5 Electric Heaters
Remove control access panel to permit site wiring to the Ecosmart
heating controller, or directly to the heating elements.
Elements have threaded connection points for linking elements
and site wiring. Elements should be linked with reference to the
appropriate wiring diagram, 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 through the apertures provided.
Screwed glands 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 heating 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 strongly 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 damage caused by an inadequate
control system.
All heaters must be wired in accordance with IEE regulations and
conform to local and national statutory requirements. The element
tray is a mains carrying component and must be earthed.
5.6 Fan Sections
Access to the fan section is via lift off panels. Cable entry must be
made through the apertures provided. Screwed glands 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, wiring 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 diagram attached to
the unit.
For star delta starting, 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, checking that it spins freely. Check all fixings are
secure.
Units must not be operated without all access panels in place –
damage to equipment or injury to personnel may result.
Units must not be operated unless control interlocks are in place –
damage to equipment may result. Test run motor for condition and
correct rotation.
Check that the correct current overloads are fitted and that the
current being drawn does not exceed the motor nameplate value.
Excessive current normally indicates that the ductwork system
resistance is different to design.
Figure 21.
0 - 10V
0V
BMS

10
Isolation - Before commencing work make sure that the unit and
Nuaire control are electrically isolated from the mains supply.
Warning - Inverter Speed Control
An Inverter is used to provide speed control. When the fan is
isolated, allow 5 minutes for the capacitors in the inverter to
discharge before commencing any work on the unit.
Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
5.7 Electrical – Ecosmart Units
Commissioning panel - Using 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 running already, press the button
once to stop the fan, press again to switch on the fan.
Note that the fan will return to normal operation after
30 seconds.
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
Cooling* GREEN: Cooling selected
Fault: LED on when a fault is present on unit.
Frost* RED: Frost condition exists
Tx LED on when the controller is transmitting data.
Rx LED on when the controller is receiving data.
* Note that this control panel is common to all the Nuaire
Ecosmart products and may have indicators for functions
that are not available in individual units – however, the unused
indicators will not be illuminated.
5.8 Settings
Setting the maximum air flow
i) Ensure the power supply is switched off and that a linkwire is
connected from the supply L to the SL terminal.
Unplug 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 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. Remove the link wire if not required.
Setting the minimum/trickle airflow rate
(Nominally 40% for S6 units 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 setting (nominally 40%) must be below
the maximum setting, otherwise the minimum setting 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 working adjustment of the fan speed by user control
and sensors, ranges between the minimum and maximum set
points.
Note :- Where third party controls are specified and fitted,
reference should be made to the control specification and
operating instructions.
It is the installer’s responsibility to ensure that such controls
are suitable for operation with the Nuaire equipment.
Nuaire will accept no liability for equipment damage resulting
from incompatible controls.
Mechanical
i) Wet systems require the setting of the coil bypass balancing
valve, set using general commissioning procedures - refer to the
specified design flow duties and any documentation attached to
the valve.
6.0 Maintenance
It is recommended that PPE is always used during the maintenance
of Air Handling Equipment – gloves, 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 discharge before commencing any work on the
unit.
6.1 Dampers
At regular intervals check that the blades move freely.
6.2 Filters
Disposable filters should be changed when fully dust laden.
Washable filters should be removed when fully dust laden and
washed in mild detergent, flushed with clean water and allowed to
dry before replacing.
Carbon filters should be replaced once carbon activation is
exhausted.
Inclined gauge manometers, where fitted, should be checked for
fluid level.
6.3 Heating and Cooling Coils
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. Traps should be checked that they are fully
primed and functioning.
Drain pans should be flushed out periodically to remove
contamination.
Note: The unit application may require particular attention to
this item – Check with Building Management personnel for
details.
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
Figure 22.

6.4 Electric Heaters
Electric heaters should be checked at regular intervals for condition
of elements, wiring 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 spraying
with a mild detergent solution for grease deposits.
Solvents, strong alkaline, acidic or any products that may be
aggressive to aluminium should not be used. Do not use cleaning
water over 50 deg 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.
Note: The unit application may require particular attention to
this item – Check with Building Management personnel for
details.
6.6 Maintenance and Cleaning of
Rotating Heat Exchangers
Maintenance of the rotor
To secure the function and performance, the face of the rotor has to
be inspected regulary 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 using hot water and a mild detergent.
Maintenace of drive unit
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 tension, first check the belt tensioner and adjust it as
much as possible. Secondly, shortening of the V-belt may be
required. The V-belt is joined together by an easily removable
mechanical lock. Ensure adjustment of the belt tensioner after
this operation.
The round belt is self tensioned and no adjustment should be needed.
Maintenace of brush sealants
Tightness between brush sealants and casing has to be checked
during inspection. The brush sealants are easily adjusted by
losening the screws and moving the brush sealant into the right
position.
V-belt, Round belt and brush sealants are all available as spare
parts.
Checking drive belt tension
To check the correct tension of a drive belt, apply a force at right
angles to the centre of the belt span sufficient to deflect the belt
16mm for every metre of span length.
The force required to deflect the ‘V’ belt should be from 0.5kg to
0.8kg.
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
All belt drive units incorporate a belt tensioning facility.
To adjust the belt tension, slacken the pinch bolts on the sides of
the motor plate. Use the motor platform pivot adjustment to
tighten and loosen the belt.
Clean impellers with a soft brush only, and remove dust/deposits
from all internal surfaces including the motor housing,
6.7 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.
7.0 Service
Service schedule (typical – will depend on site
conditions)
6 MONTHS 12 MONTHS
FILTERS ✔or ✔
DAMPERS ✔
DAMPER ACTUATORS ✔
BELT DRIVES ✔
FILTER MANOMETER FLUID ✔
VENT WATER COILS ✔
COIL FINNED SURFACES ✔
CHECK DRAIN LINES + DRIP TRAY ✔✔
CLEAN & FLUSH DRAIN PANS Building
Schedule ? ✔
NUTS, BOLTS, FIXINGS SECURE ✔
FAN BEARINGS ✔
ELECTRIC HEATERS ✔
ELECTRICAL WIRING ✔
FAN IMPELLER ✔
GENERAL ✔
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 remaining 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 general good practice.
9.0 Spares
Spare parts and replacement components, and general advice are
available from the Nuaire Ltd Service department.
Telephone [phone]
Fax [phone]
11 Leaflet Number 671423 October 2010
Installation, Operating and Maintenance Instructions XBOXER Thermal Wheel
Figure 23.

12 Leaflet Number 671423 October 2010
DECLARATION OF INCORPORATION AND INFORMATION FOR SAFE INSTALLATION,
OPERATION AND MAINTENANCE
To comply with EC Council Directives 98/37/EC Machinery Directive and
2004/108/EC (EMC).
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,
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 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
duct work systems. They must not be used to support the ductwork.
5.0 INSTALLATION REQUIREMENTS
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.
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, lighting or power cables and
any cables not intended for use with this product.
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 documenta-
tion.
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.
INFORMATION FOR SAFE INSTALLATION, OPERATION AND MAINTENANCE
OF NUAIRE VENTILATION EQUIPMENT
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 Machinery Directive.
Designation of machinery: XBOXER-TWB Thermal Wheel
Machinery Types: Heat Recovery
Relevant EC Council Directives: 98/37/EC as amended by 98/79/EC
(Machinery Directive)
Applied Harmonised Standards: BS EN ISO 12100-1, BS EN ISO 12100-2,
EN294, EN60204-1, BS EN ISO 9001
Applied National Standards: BS848 Parts One, Two and Five
Signature of manufacture representatives:
Name: Position: Date:
1) C. Biggs Technical Director 20. 07. 07
2) W. Glover Manufacturing Director 20. 07. 07
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.