NuAire BESPOKE BOXER User manual

1
22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXER
Air Handling Units
Installation Manual
1.0 SAFETY INFORMATION
• The provision of the electrical supply and the connection of the unit to the electrical supply must
be carried out by a qualified electrician.
• This unit must be earthed.
• All-pole disconnection from the mains as shown in the wiring diagram must be incorporated
within the fixed wiring and shall have a minimum contact separation of 3mm in accordance with
latest edition of the wiring regulations.
• Isolate from power supply before removing any covers. During installation / maintenance ensure
all covers are fitted before switching on the mains supply.
• Ducting must be securely fixed with screws to the spigot to prevent access to live parts. Duct
runs terminating close to the fan must be adequately protected by suitable guards.
• Sharp edges need to be handled with caution; most of the air handling equipment will contain
sharp edges on the internal and external surfaces. Care should be taken to ensure that all
personnel are aware of this and precautions are implemented to ensure no wounding is caused.
• This appliance should not be used by children or persons with reduced physical, sensory or
mental capabilities or lack of experience and knowledge, unless they have been given supervision
or instruction concerning the safe use of the appliance by a person responsible for their safety.
Children shall not play with the appliance. Cleaning and user maintenance shall not be carried
out by children.
1.1 Symbols
GENERAL WARNING
Signifies a general warning regarding hazard specified by supplementary information.
ELECTRIC SHOCK
This unit must be completely electrically isolated before any panels are removed. Check
mains supply and control connections.
ROTATING PARTS
This unit contains fast moving rotational parts which may start automatically. It is the
sole responsibility of the installer to adequately guard these components.
REFER TO INSTRUCTION MANUAL
Read and understand the installation and maintenance manual before installing,
operating or maintaining this product.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation 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 product:
•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.
1.4 Activity Guidelines
Component parts are usually not fitted with safety guards i.e.
fan inlet. The casing of the unit acts as a protective guard for all
component parts.
Please ensure that prior to commencing any activity, the following
guide lines are adhered to:
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.
During installation, commissioning, operation and maintenance of
an air handling unit, operatives may be exposed to hazards including,
rotating components, refrigerants and high voltage electricity. If
misused or handled improperly, each of these items has the potential to
cause bodily injury or death.
Identification and recognition of inherent hazards is the obligation of
responsible personnel. They must protect themselves and others by
proceeding with care and consideration to health and safety measures.
All risk assessments have been carried out and are in place prior to
carrying out any activity.
The relevant protective equipment and attire is worn by each relevant
member of staff.
That the unit Nuaire have supplied meets the standards written in the
technical specification.
The necessary lifting gear and site plant is available to lift and position
the unit in accordance to the technical drawings.
The Plant is fully isolated from the mains supply and allowed to run
down for a minimum of five to ten minutes before opening any access
door prior to the commencement of any maintenance work.
When maintenance work is finished, please ensure that the unit is left
in a clean state, and all access doors /panels are fastened and locked
correctly (locked handle returned to holder).
At no point should a unit be used for the storage of tools or working
equipment.
2.0 INTRODUCTION
The information contained in this document provides details of
installation, operation and maintenance for installers and users of the
BESPOKE BOXER Air Handling Units.
The BESPOKE BOXER range of units are manufactured from Aluzinc
corrosion resistant steel, with either 30 or 50mm double skinned panels
and anodized aluminium frame; Mechanical strength, D1; Leakage class,
L2; Thermal transmittance, T4; Thermal bridging, TB4.
The range has high efficiency centrifugal fans and where applicable,
high efficiency thermal wheel, plate heat exchanger or run-around
coils. A G4 pre-filter and F7 main filter on supply as standard with M5
filtration of the extract air. BPS range includes optional heating (LPHW,
Electric or Gas Fired) and cooling (Chilled water, DX).
A wide selection of ancillaries are available, including attenuators,
dampers, frost coils, recirculation modules and weather terminals.
BESPOKE BOXER units are delivered to site control free as standard,
allowing them to be integrated with control systems supplied by
others.
General information regarding performance and specification for the
equipment can be obtained from our technical literature, and/or project
specific documentation.
2.1 Receipt Of Equipment
To ensure that the delivery vehicle is loaded according to the
planned method of offloading, Nuaire should be notified at order
stage to ensure coordination.
Where possible, double deck sections leave Nuaire fully assembled.
For more information on unit delivery please contact our
commercial orders team on 02920 858 200.
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.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
2 Typical Base Frame Detail
Section
length
Section
length
Section
length
Section width
50.0
50.0
50.0
50.0
50.0
100.0
100.0
100.0
Overall unit length
76, 100, 150 or 200
A (1:5)
CENTRE SUPPORT CAN BE ON EITHER SIDE OF CENTRE LINE
50mm x 50mm Lifting hole
50.0
50.0
A
2.4 Equipment Protection
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.
2.5 Equipment Storage
Units that are intended for external locations are generally not
fully weatherproofed until their installation, including ductwork
connections, is complete.
The equipment must be stored in a dry, internal location. Ductwork
connection apertures should be sealed against the ingress of dust,
water and vermin. Do not stack units, modules or components that are
not designed to be stacked.
Where fans are to be stored or bonded for extensive periods either in
warehouse, under site conditions or in the installed state, we make the
following additional recommendations:
•Motors should be stored at ambient temperatures between
-16°C and +40°C and at relative humidity (RH) below 90%RH.
•Fans should be retained in their original packaging and stored
on level ground.
•Fans should be protected from damage, excess moisture and
ingress of dirt, dust or other contaminants.
•Relax the belt tension on belt driven equipment.
•Turn fan and motor shafts at three monthly intervals to
prevent the brinelling effect on the bearings. Brinelling is a
flattening or settlement of the shaft in the bearing housing.
The conditions above will apply and any deviation from them could
nullify the warranty.
2.2 Handling Of Equipment
The images in Figure 1 show examples of typical lifting methods.
Actual lifting plan and risks must be assessed by competent
personnel before moving the unit.
When offloading, care must be taken to ensure that the AHU is
kept level at all times.
To ensure that no roof damage occurs additional timber packaging
must be used.
The weight of the unit modules and palletised items are 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. Items should only be lifted by competent personnel
following appropriate risk assessment.
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 casings. Care
should be taken to ensure the units remain upright and level at all
times.
Where channels and/or support frames are bolted to the underside of
the unit casing, slings or fork-lift arms should be positioned in the base
frame lifting apertures, full details of which are in the following section.
If lifting lugs / eyes have been supplied / or fitted it is recommended
that they are used.
Assembly with
base frame.
Palletised. Forklift.
Slings via spreaders fitted to
unit with base frame.
1 Lifting Methods
2.3 Base Frame Lifting Points
When units are constructed of multiple modules each module will have
its 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 2).

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
3.0 MECHANICAL INSTALLATION
Installation must be carried out by competent personnel, in accordance
with good industry practice, with the appropriate authority and in
conformance with all statutory and governing regulations.
The unit should stand upright and level on the floor, foundation or
supporting steelwork which should be rigid, flat and level and should
be capable of supporting the weight of the unit including water or
refrigerant in the coils.
Nuaire takes no responsibility for the coordination of support.
3.1 Installation Location
To prevent possible reintroduction of contaminated air through the
outside air intake, the unit should be located away from building flue
stacks or exhaust ventilators.
Once assembled and in position, sufficient free space must be available
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); or half the overall unit width (horizontally arranged units) +
100mm be allowed. For units with a horizontal layout, access is
typically required to both sides of the unit casing.
Sufficient clearance for U-traps on condensate drain and overflow
connections should also be considered by the purchaser.
3.2 Air Leakage
Loading, transportation, off loading and site positioning can cause
the air handling unit structures to move, therefore panel seals will not
always remain fully intact.
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.
3.3 Modular Unit Section Joints
All sections should be accurately aligned and adjoined prior to bolting
together using the fixings and gaskets provided by Nuaire.
Modular units are supplied with matching internal connection plates
with a single bolt hole provided to each corner through which the
sections are bolted together. Unit access panels must be removed to
perform the assembly operation. Plates will either have clearance holes,
or one face with a threaded insert and the other with a clearance hole.
In instances of restricted access to the internal corner bolts, external
clamps can be provided to facilitate external connection of modules.
A sealing gasket should be applied as necessary to the mating faces of
the unit frames before bolting together.
Air leakage, air blow marks to the unit casings and unacceptable noise
levels could result if the correct installation procedures are not adhered
to.
3 Joint Details
Connection plate
Fixing rod
Inner panel skin
Pentapost frame
Outer panel skin
Panel infill
Optional external clamp
Fixing rod.
Fixing rod / External clamp detail.
Optional external clamp.
3.4 Weather Resistant Units
Weather resistant units in multiple sections will have sectional roof
components that must be fitted and sealed after the unit sections
are bolted together. All necessary nuts, bolts, washers and sealant are
supplied with each unit and are normally bagged and located within the
fan section. Suitable mastic sealant is to be provided by others.
The equipment must not be exposed to the weather in an unassembled
or partially assembled state. All ductwork, sealing and assembly
work must be completed before the unit can be considered weather
resistant.
Where the weatherproof roof assembly of two sections meet, a
weatherproof cover strip must be applied to seal the seam, this will be
supplied with the unit.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
4 Units With Weatherproof Roofs
Above Left: Horizontal unit with weather kit.
Above Right: Vertical (Stacked) unit with weather kit.
Below: Roof assembly detail.
3.5 Thermal Wheel Transport Packing
Thermal wheel modules can be delivered with transport packing blocks,
ensure any transport blocks are removed prior to operation of the
thermal wheel.
The thermal wheel belt is unhooked to prevent the thermal wheel belt
from stretching during transportation.
The thermal wheel motor is attached via a hanging motor bracket. To
install the belt lift the spring motor upwards, hook the belt onto the
pulley and slowly release the motor.
Ensure that the rotation sensor is aligned with the sensing studs,
as this can become misaligned during transport/installation thus
causing a fault signal.
3.6 Connections
3.6.1 Ductwork
Nuaire do not provide ductwork connections with units, instead
the open ended framework should be utilised. Spigots are available
as an option; refer to technical documents for information relating
specifically to the manufactured unit.
3.6.2 Coils
When connecting coils, special care is needed to allow for expansion
and contractions. Prior to any equalising connection, ensure that the
thermostatic expansion valve for the DX coil is securely fitted.
Each coil section should be trapped and special care should be taken to
ensure that there are no vertical rising condense lines, unless pumped.
If a frost coil is not fitted then appropriate control methods must
be taken to prevent the coils, filters and other equipment from
freezing (by others).
3.6.3 Pipework
Care should be taken to ensure that all pipework is adequately
supported, therefore ensuring that no additional weight is added to the
unit. Extra precaution should be taken to prevent pipe damage on site,
as the fragile pipework will protrude from the side of the unit.
3.6.4 Condensate Drains
Modules that incorporate heat recovery, cooling coils or humidifiers
may produce condensation during use. An insulated drip tray and drain
connection is provided, and should be connected to a suitable drainage
point.
Where plate heat exchangers are in use, condensate drainage points are
provided. It is the installers’ responsibility to ensure connection to the
appropriate trap and drainage. Due to the bespoke nature of these units
condensate connection locations can vary during the design process
and should be confirmed on an individual basis.
Horizontal plate heat exchangers have 2x 22mm drain connections.
Connections are typically located on the underside of the PHX module
at the extract inlet and extract outlet (Figure 5).
Vertical plate heat exchangers have 2x 22mm drain connections.
Connections are typically located at the bottom of the access side of
the PHX module (Figure 6).
Provision may be required, and if so, should be made, for the fitting of a
correctly sized cleanable trap to each drain connection.
5 Condensate Connections For Horizontal Units With PHX
jjjj
Side View
End View
1x 22mm Condensate Connection
1x 22mm Condensate Connection
6 Condensate Connections For Vertical Units With PHX
2 x 22mm Condensate Connections
Access Side View

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
Under Negative Pressure
If the condensate tray is located at the inlet side of the fan (i.e. under
negative pressure) then calculate the values of A & B as shown below
(Figure 7).
10Pa = 1mm H2O
A = Fan inlet pressure (mm H2O) +25mm (minimum). Allow 100mm
for these units if pressure is unknown.
B = A/2 (minimum).
Under Positive Pressure
If the condensate tray is located at the outlet side of the fan (i.e. under
positive pressure) then calculate the values of A & B as shown below
(Figure 7).
A = 25mm (minimum).
B = Fan outlet pressure (mm H2O) + 25mm (minimum).
Allow 100mm for these units if pressure is unknown.
7 Condensate Trap Dimensions
Hand tight plug
B
A
condensate
From
drain pan Hand tight plug C
onnect to
ventilated
downpipe
to drain
3.7 Fan Transit Brackets (AC Motors)
Transit brackets are factory fitted to prevent the blowers moving during
transport and must be removed to prevent excessive vibration during
operation. The specific location and number of transit brackets varies by
unit. Check the unit drawing for the location and number of blowers.
Before use ensure the transit brackets have been removed from each
blower within the unit (Figure 8).
•Loosen and remove the transit bracket bolt.
•Remove the transit bracket away from the anti-vibration mount.
Repeat for each bolt.
•Store the transit brackets and bolts in a safe location if required for
future use.
Transit Bracket
Transit
Bracket
Bolt
8 Fan Transit Brackets (AC Fans)
3.8 Filters
Filters will be provided in banks on suitable slide rails, so that they
can be withdrawn. Magnehelic gauges are offered as standard unless
otherwise instructed.
3.8.1 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.
3.8.2 Panel & Bag Filters with Side Withdrawal
Insert the filters by sliding them into the railing provided. If specified,
blanking filters are fitted at the end of the railing.
9 Side Withdrawal Filters
Capping strip
3.8.3 Panel & Bag Filters with Front Withdrawal
Insert filters squarely into the frames and retain using retaining P-clips.
10 Front Withdrawal Panel Filters
11 Front Withdrawal Bag Filters

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
3.9 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.
3.10 Final Inspection
•Thoroughly inspect the unit after installation is complete.
•The inside of the unit should be checked; any objects which may
have been left should be cleared.
•Check fan impellers, scrolls and outlets.
•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.
4.0 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.
Ensure suitable earth bonding is maintained on all AHU sections.
4.1 Wiring (If Applicable)
4.1.1 AC Motor Fans
Inverter speed control is required for these units and can be provided by
Nuaire as optional extras, any inverters should be configured to match
the design and running frequency that is provided on the datasheet of
each specific fan.
Care should be taken to ensure that the rotation of three phase motors
correspond with the direction shown on the frame.
All electrical connections to the fan are to be made using flexible cable
and containment materials to allow for the movement of anti-vibration
mounts.
12 Typical Fan (AC Motor) Wiring
L1 L2 L3
U1 W1 PEV1 U2 W2V2
3 Phase only
Inverter Speed Control
Motor
Terminal
Connections
Inverter Drive
INPUT OUTPUT
Notes:
Inverters are typically unconfigured, and require configuring
to suit project specific fans and control applictions.
Internal Factory Connection
Mandatory Customer Connection
Key:
U1 W1V1
400V 3 phase 50Hz supply
Motor
3 Phase
U1 W1
V1
4.1.2 EC Motor Fans
13 Typical Fan (EC Motor) Wiring
No. Conn. Desig. Function / Assignment
KL1 1 L1 Mains supply connection, supply voltage 3~380-480 VAC;
50/60 Hz
KL1 2 L2 Mains supply connection, supply voltage 3~380-480 VAC;
50/60 Hz
KL1 3 L3 Mains supply connection, supply voltage 3~380-480 VAC;
50/60 Hz
PE PE Earth connection, PE connection
KL2 1 NO Status relay, floating status contact; normally open; close
with error
KL2 2 COM Status relay; floating status contact; changeover contact;
common connection; contact rating 250 VAC / max. 2 A
(AC1) / min. 10 mA
KL2 3 NC Status relay, floating status contact; break with error
KL3 1 RSA Bus connection RS-485, RSA, MODBUS RTU; SELV
KL3 2 RSB Bus connection RS-485, RSA, MODBUS RTU; SELV
KL3 3/10 GND Signal ground for control interface; SELV
KL3 4 Ain1 U Analogue input 1, set value: 0-10 V, Ri = 100 kΩ,
parametrisable curve, only usable as alternative to input
Ain1; SELV
KL3 5 + 10 V Fixed voltage output 10 VDC, +10 V ±3%, max. 10 mA,
short-circuit-proof, power supply for external devices (e.g.
potentiometer), SELV
KL3 6 Ain1 I Analogue input 1, set value: 4-20 mA; Ri = 100 Ω,
parametrisable curve, only usable as alternative to input Ain1
U; SELV
KL3 7 Din1 Digital input 1: enabling of electronics, Enabling: open pin
or applied voltage 5-50 VDC. Disabling: bridge to GND or
applied voltage <1 VDC. Reset function: triggers software
reset after a level change to <1 VDC; SELV
KL3 8 Din2 Digital input 2: parameter set switch 1/2, according to
EEPROM setting, the valid/used parameter set can be
selected via bus or via digital input DIN2. Parameter set
1: open pin or applied voltage 5-50 VDC. Parameter set 2:
bridge to GND or applied voltage <1 VDC; SELV
KL3 9 Din3 Digital input 3: controller function of integrated controller,
according to EEPROM setting, the controller function of the
integrated controller is normally/inversely selectable per bus
or per digital input. Normal: open pin or applied voltage 5-50
VDC. Inverse: bridge to GND or applied voltage <1 VDC; SELV
KL3 11 Ain2 U Analogue input 2, actual value: 0-10 V, Ri = 100 kΩ,
parametrisable curve, only usable as alternative to input
Ain2; SELV
KL3 12 + 20 V Fixed voltage output 20 VDC, +20 V +25/-10%, max. 50 mA,
short-circuit-proof, power supply for external devices (e.g.
sensors); SELV
KL3 13 Ain2 I Analogue input 2, actual value: 4-20 mA, Ri = 100 Ω,
parametrisable curve, only usable as alternative to input Ain2
U; SELV
KL3 14 Aout Analogue output 0-10 VDC, max. 5 mA, output of the current
motor level control coefficient / motor speed parametrisable
curve; SELV

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
4.1.3 BMS Differential Pressure Switch
An external power supply delivering 10-35 VDC with a minimum
current capability of 40ma must be used to power the control loop in
which the PDGAUGE2/BMS is connected.
If the receiver requires a 1-5 volt input, insert a 250 ohm, 1/2 watt
resistor in series with the current loop but in parallel with the receiver
input (Figure 14). RL becomes the 250 ohm resistor and point X and Y
are connected to the receiver input, point X being positive (+) and point
Y negative (–) or ground.
14 BMS Differential Pressure Switch Wiring
PDGAUGE2/BMS
POWER
SUPPLY
10-35 VDC
RECEIVER (RL)
NOTE: RECEIVER MAY BE IN SERIES WITH
+ OR - LEG OF CONTROL LOOP
RL MAX = V
XY
-
+
-
+
PS - 10.0V
20 mA DC
MAXIMUM VALUE (1250)
Mandatory Customer Connection
Optional Customer Connection
Key:
4.1.4 Bulkhead Lights
Lights are designed for permanent connection to fixed wiring. This
should be either a suitable lighting circuit (protected with a 5 or 6 Amp
MCB or fuse) or a fused spur (with a 3 Amp fuse) via a fused connection
unit.
15 Bulkhead Light Wiring
COM
1 2
EARTHING
N
LOOP
L
L
N
EARTH
FROM
LIGHT
TO
INTERNAL
LIGHT
Internal Factory Connection
Mandatory Customer Connection
E
Mains
230V
50Hz
Key:
4.1.5 Electric Heater Wiring
For models with electric heating, the heating circuit is powered by a
higher current, 400Vac 50Hz 3 phase & Neutral supplies. This must be
isolated to the unit and fitted with appropriate overcurrent 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.
16 Typical Electric Heater Wiring
E
1
2
3
N
AIR-FLOW PROVING SWITCH
PIPED TO OUTSIDE
Internal Factory Connection
Mandatory Customer Connection
BROWN
GREY
BLUE
L1
L2
L3
STAR POINT
NO NEUTRAL CONNECTED
2A
2
1
3
4
5
6
N
L
C1
MANUAL RESET
OVER-HEAT
CUT-OUT
L1 L2 L3
AUTO RESET
OVER-HEAT
CUT-OUT
351 26 4
PUSH
TO RESET
HEATER
E
EARTH BOLT
BLACK BROWN
BROWN
0-10V
0V
REMOTE
START
SIGNAL
FUSED 400V
POWER SUPPLY
FROM LOCAL ISOLATOR
SCREENED
TEMPERATURE
CONTROL INPUT
HEATER TRIPPED
VOLT-FREE SIGNAL
CLOSED = HEALTHY
OPEN = TRIPPED
1234
L1 LOAD1 L2
L3/LOAD3
LOAD2
TH
Key:
4.1.6 Thermal Wheel
The thermal wheel incorporates a purge section and is fitted with a
rotational drive. Any temperature sensors and enabling signal are to be
provided by others.
A frequency converter with a modular design is used as the control
unit; it can adjust the speed of three-phase motors. The control unit is
delivered ready for operation with the factory-set parameters. Various
settings can be changed with an optionally available operating unit.
Error messages can be read out directly at a flashing LED.
The power unit is protected from under voltage, over voltage or
non-approved converter temperature.
Recommended tightening torque on terminals 0.5 Nm; maximum
tightening torque 0.8 Nm.
MicroMax370
Output
Motor
Side
Maximum motor power kW 0.37
Nominal output current A 1.9
Maximum output voltage V 3 x 0-230
Output frequency Hz (Fixed)4...40-100/150
Mains
Input
Rated voltage V 1x230-240 +/-15%
Mains frequency Hz 50/60
Fuses A T 10
General
Data
Protection rating IP54
Ambient temperature °C -20…45
Air humidity kg 1.1
Dimensions H x W x D mm 198 x 164 x 60

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
U V W T T 13 14 15L N 2 3 9 10
s
w1 2 34 5 br
M
3 ~
1 x 230 V 3 x 230 V
Max 180 W
Thermal
contact
(Max 8 A /
250 V AC)
Manual
speed
Rotation
monitor
0-10 V
+ -
!
2 3
17 Typical Thermal Wheel Wiring
Terminal Description
L, N, PE Input Voltage - Protective earth must always be connected.
U, V, W Motor - 3Ph induction motor wired for 3x230V.
Direction of rotation is changed by switching 2 of the phases.
T, T Thermal Contact - Protects motor from overheating. Must be
jumped if the temperature switch is not connected.
13, 14, 15 Alarm Relay - Closes between 14-15 on Alarm or
voltage drop-out. Max 8A resistive load / 250 V AC.
2, 3 Input Signal - 0-10 V. Terminal 2 positive, Terminal 3 negative.
Magnet installed with south side (S) towards transmitter. Max.
gap 15mm.
9, 10 Rotation Monitor - White to Terminal 2, Brown to Terminal 3
A1, A2 Manual Speed - Max RPM when closed regardless of input signal.
5.0 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.
5.1 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.
5.2 Fan and 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.
Inverters should be configured to match the design and running
frequency that is provided on the datasheet of each specific fan.
6.0 MAINTENANCE
Before commencing work make sure that the unit is electrically
isolated from the mains unit and sufficient time has passed to
allow the fans to run down.
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.
6.1 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.
•The unit power supply is isolated to prevent uncontrolled
running of the fan 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. In cases of heavy duty operation, maintenance
intervals are to be established by the operator.
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.
6.1.1 General Fan Maintenance
•Access to the fan is normally gained by opening the hinged
access doors, in some instances there will be a turn mechanism
(1/4 turn) to release and lift panels.
•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.
•Check all fixings are secure.
•In accordance with BSEN1886:2007 access doors to the fan
modules are lockable. As such, it must be ensured that a
padlock is used to prevent access when fan is in operation, or
coming to rest (padlock supplied by others).
6.1.2 Bearings
Fan bearings should be manually checked at regular intervals for
condition. Standard fan bearings are supplied as ‘sealed for life’ and
have an anticipated life of 40,000 hours.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
6.1.3 Rotation
Ensure that the directions of rotation of the driving motor are checked
and operating correctly.
6.2 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.
6.3 Humidifiers
Any areas of corrosion should be identified and repaired, any sediment
from the drain tray and connections should also remain clean.
6.3.1 Spray Coil/Washer Humidifier Module
All nozzles should be checked and cleaned as necessary.
Care should also be taken to ensure that the pump is handling the
correct volume of water and is in smooth and quiet operation. The
pump inlet strainer should also be clean. Check for leaks, pay special
attention to the shaft seal.
Remove all filters and clean and ensure that the motor is not
overheating.
6.4 Coils
6.4.1 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 pipework
depending on the installation.
Frost protection must be incorporated on shut down and fresh air
conditions to avoid coil freezing. Ideally, where the system is at risk of
frost damage, the addition of a proprietary antifreeze solution to the
water is recommended.
Pipe-work connections should be made to the unit using appropriate
techniques, and must be independently supported. The connections
should be pressure tested.
6.4.2 DX
Direct expansion coils must be fitted with a correctly sized thermostatic
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.
6.5 Gas Fired Heater
If a gas fired heater is intended to be used with low air on temperature
please discuss with Nuaire prior to order placement to ensure a suitable
component selection.
6.6 Plate Heat Exchangers
The plate heat exchanger 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.
6.7 Thermal Wheel Heat Exchangers
After the 2-3 weeks of operation, and at least once per year, ensure the
following maintenance is performed.
•Check that rotor is vertical and centred in casing. Adjust vertical
and horizontal position if needed.
•Check the thermal wheel spins freely.
•Adjust sealing to ensure contact with the rotor and side plates.
Replace brush sealing if it is worn.
•Check that motor bracket is in 20-45° angle from horizontal line.
•Adjust length of drive belt if needed.
•Check condition of belt and belt lock (joint).
20-45°
18 Thermal Wheel Belt
6.8 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:
•Exhaust heat recovery coil.
•Cooling coil.
•Humidifier condensate drip tray water.
•Evaporative humidifier.
•Cooler drains.
•Water reservoirs.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
6.9 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.
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
allowing elements to cool on shut down.
6.10 Bulkhead Lights
Ensure that lights are switched off and isolated before checking or
changing the lamp.
6.11 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.
6.12 Maintenance Schedule
6.12.1 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.
•All dampers should be rotated and lubricated as necessary.
6.12.2 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.
6.12.3 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.
7.0 WARRANTY
The 1 year warranty starts from the day of delivery and includes parts
and labour for the first year.
This warranty is void if the equipment is modified without
authorisation, is incorrectly applied, misused, disassembled, or not
installed, commissioned and maintained in accordance with the details
contained in this manual and general good practice.
The product warranty applies to the UK mainland and in accordance
with Clause 14 of our Conditions of Sale. Customers purchasing from
outside of the UK should contact Nuaire International Sales office for
further details.
Failure to maintain the unit as recommended will invalidate the
warranty.
8.0 END-OF-LIFE AND RECYCLING
Where possible Nuaire use components which can be largely recycled
when the product reaches its end-of-life:
•Fans, motors, controls, actuators, cabling and other electrical
components can be segregated into WEEE recycling streams.
•Sheet metal parts, aluminium extrusion, heating/cooling coils and
other metallic items can be segregated and fully recycled.
•EPP, plastic ducting, nylon corner pieces, plastic heat exchangers,
packaging material and other plastic components can be
segregated into mixed plastic and widely recycled.
•Cardboard packaging, wood, used filters and other paper
components can be largely recycled or fully processed in energy
from waste centres.
•Remaining Items can be further segregated and processed in
accordance with the zero waste hierarchy. Please call After Sales
Support for further information on items not listed above.
Ensure that Nuaire product is made safe from any electrical / water
/ refrigerant supplies before dismantling commences. This work
should only be undertaken by a qualified person in accordance with
local authority regulations and guidelines, taking into account all
site based risks.
9.0 AFTER SALES AND REPLACEMENT PARTS
For technical assistance or further product information, including spare
parts and replacement components, please contact the After Sales
Department.
If ordering spares please quote the serial number of the unit together
with the part number, if the part number is not known please give a full
description of the part required. The serial number will be found on the
identification plate attached to the unit casing.
Telephone [phone]
[e-mail]
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.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
10.0 SERVICE CHART
3 / 9 Month Service 6 Month Service 12 Month Service
Symbol Action Date
Initials Action Date Initials Action Date Initials
Damper
/ Air
recirculation
section
Check the damper
performance. 3
Check the damper
performance.
Clean the damper.
Check the damper
performance.
9
Filter Check the pressure
drop and change the
filter if necessary.
3
Check the pressure
drop and change the
filter if necessary.
Check the pressure drop and
change the filter if necessary.
9
Thermal
Wheel
Heat
Exchanger
Rotor Spins Freely.
Check condition of
belt and belt lock
(joint).
3
Adjust sealing to
ensure contact with
the rotor and side
plates. Replace brush
sealing if it is worn.
Adjust length of drive
belt if needed.
Check that rotor is vertical
and centred in casing. Adjust
vertical and horizontal
position if needed.
Check that motor bracket
is in 20-45° angle from
horizontal line.
9
Plate Heat
Exchanger
General inspection.
Check the damper
performance.
3
Clean the heat
exchanger unit.
Clean the heat exchanger unit,
damper and casing.
9
Heat Pipe
Exchanger
General inspection.
Check the damper
performance.
3
Clean the finned unit. Clean the finned unit, damper,
drain tray and casing.
9
Air Heaters
Air Coolers
General inspection.
3
Clean the finned unit
and the electric heater
elements.
9
Humidifier
IHUMID
Inspect the:
Casing, Humidifier
fills, Droplet
eliminator, Water
filter, Water tray,
Spray pipes and
Water flow.
3
Inspect the:
Casing, Humidifier fills,
Droplet eliminator,
Water filter, Water
tray, Spray pipes,
Water trap, Water flow
and Constant-flow
valve.
Inspect the:
Casing, Humidifier fills,
Droplet eliminator, Water
filter, Water tray, Spray pipes,
Water trap, Water quality,
Water flow and Constant-
flow valve.
9
Fans General inspection.
3
General inspection. Clean the fan impeller,
casing, unit casing. Check the
bearings.
9
Casing Check that the doors are tight.
Clean inside and outside if
necessary.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
DECLARATION OF INCORPORATION AND INFORMATION FOR SAFE INSTALLATION,
OPERATION AND MAINTENANCE
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. All parts except for
moving parts requiring the correct installation of safety guards comply with the
essential requirements of the Machinery Directive. 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: BOXER
Machinery Types: Air Handling Units
Relevant EC Council Directives: 2006/42/EC (Machinery Directive)
Applied Harmonised Standards: BS EN ISO 12100-1, BS EN ISO 12100-2,
BS EN60204-1, BS EN ISO 9001,
BS EN ISO 13857
Applied National Standards: BS848 Parts 1, 2.2 and 5
Signature of manufacture representatives:
Name: Position: Date:
1)C. Biggs Technical Director 26. 01. 11
2)A. Jones Manufacturing Director 26. 01. 11
To comply with EC Council Directives 2006/42/EC Machinery Directive and 2014/30/EU (EMC).
To be read in conjunction with the relevant product documentation (see 2.1)
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 e.g.
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.
4.4 Local Environment - Humidity. Ambient humidity (the humidity at the unit’s installed
location) shall be within the range: 10 to 95% (for controls, non-condensing).
Air humidity (the humidity of the air passing through the unit) shall be within the
range: 10 to 95% (for controls, non-condensing).
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 (e.g. 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 documentation.
7.0 OPERATIONAL REQUIREMENTS
7.1 Equipment access panels must be in place at all times during operation of the unit, and
must be secured with the original fastenings.
7.2 If failure of the equipment occurs or is suspected then it should be taken out of service
until a competent person can effect repair or examination. (Note that certain ranges of
equipment are designed to detect and compensate for fan failure).
8.0 MAINTENANCE REQUIREMENTS
8.1 Specific maintenance requirements are given in the relevant product documentation.
8.2 It is important that the correct tools are used for the various tasks required.
8.3 If the access panels are to be removed for any reason the electrical supply to the unit
must be isolated.
8.4 A minimum 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.
Note: All standards used were current and valid at the date of signature.

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22. 04. 21. Document Number 671506
Nuaire | Western Industrial Estate | Caerphilly | CF83 1NA | nuaire.co.uk
BESPOKE BOXERInstallation Manual
NOTES

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BESPOKE BOXERInstallation Manual
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BESPOKE BOXERInstallation Manual
NOTES