BESPOKE BOXER AIR HANDLING UNITS Installation and ...nuaire.info/IandM/671506.pdf · AIR HANDLING UNITS Installation and Maintenance Instructions ... 1.4 Unit Storage The equipment

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BESPOKE BOXERAIR HANDLING UNITSInstallation and Maintenance Instructions

The EMC Directive 2014/30/EU The Low Voltage Directive 2014/35/EU

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INVERTERCONTROL PACK

IHUMIDINVERTER

CONTROL PACKW

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Nuaire: A Trading Division of Polypipe Limited

Western Industrial Estate

Caerphilly

United Kingdom

CF83 1NA

T: 029 2085 8200

F: 029 2085 8300

E: [email protected]

W: www.nuaire.co.uk

09. 05. 17. Leaflet Number 671506

Health & SafetyNuaire intend that this manual and any other supportive documentsthat may be mentioned should be read and understood by authorisedoperating and service personnel before performing any task related tothe installation, commissioning and maintenance of Nuaire BOXERAir handling units and any associated components.

The operative / service personnel should comply with good industrypractice, the appropriate authority and conformance with allstatutory and governing regulations.

The unit must be manually isolated from the electrical supply and aperiod of five minutes allowed to elapse before any access door isopened for the purpose of general maintenance.

Sharp edges need to be handled with caution; most of the airhandling equipment will contain sharp edges on the internal and external surfaces. Care should be taken to ensure that allpersonnel are aware of this and precautions are implemented to ensure no wounding is caused.

To help operating and service personnel perform tasks safely, pleasepay attention to the notes throughout this document (see below forexample).

All notes are designed to alert the reader to potential hazards.

Delivery / Receipt of PlantAll equipment is inspected prior to despatch and leaves the factory ingood condition.

Upon receipt, the unit should be examined to ensure that no visibledamage has occurred whilst in transit, and the advice note checked toensure that all items have reached the location as requested.

Any damaged goods, or an incomplete delivery should be discussedwith the driver prior to offloading. It is the responsibility of bothparties to check all goods against the order/delivery details.

In a case where any of the above becomes an issue, Nuaire Limitedshould be notified within three days of receipt, with a writtenconfirmation sent within seven days.

Please ensure that prior to commencingany activity, the following guide lines areadhered to:• During installation, commissioning, operation and

maintenance of an air handling unit, operatives may beexposed to hazards including, rotating components, refrigerants and high voltage electricity. If misused orhandled improperly, each of these items has the potentialto cause bodily injury or death.

• Identification and recognition of inherent hazards is theobligation of responsible personnel. They must protectthemselves and others by proceeding with care andconsideration to health and safety measures.

• All risk assessments have been carried out and are inplace prior to carrying out any activity.

• The relevant protective equipment and attire is worn byeach relevant member of staff.

• That the unit that Nuaire have supplied meets the standardswritten in the technical specification.

• The necessary lifting gear and site plant is available tolift and position the unit in accordance to the technicaldrawings.

• All electrical equipment is connected and earthed inaccordance with I.E.E. Regulations.

The Plant is fully isolated from the mains supply andallowed to run down for a minimum of five to ten minutesbefore opening any access door prior to thecommencement of any maintenance work.

• When maintenance work is finished, please ensure thatthe unit is left in a clean state, and all access doors /panels are fastened and locked correctly (Locked handlereturned to holder).

• At no point should a unit be used for the storage of toolsor working equipment.

Installation and Maintenance Instructions BESPOKE BOXER Air Handling Units

2 09. 05. 17. Leaflet Number 671506

Information contained in this format is designed to outline important Notes, Dangers, Cautions

and Warnings.

Component parts are usually not fitted with safety guardsi.e. fan inlet. The casing of the unit acts as a protective guard

for all component parts.

ContentsSection Content Page number

Health & Safety 2

Delivery and Receipt of Plant 2

1.0 INTRODUCTION 4

1.1 Offloading 4

Methods of Lifting 4

1.2 Base Frame Lifting Points 5

1.3 Unit Protection 5

1.4 Unit Storage 5

1.5 Lubrication 5

2.0 INSTALLATION 6

2.1 6

2.2 6

2.3 6

2.4 7

2.5 7

2.5.1 7

2.5.2 7

2.5.3 7

2.5.4.1 7

2.5.5 9

2.5.6

Location

Air Leakage

Unit Joints

Weather Resistant Units

Connections

Ductwork

Coils

Pipework

Condensate Drain

Condensate Connections - PHX

Electrical

Motor Wiring Diagrams 9

Three Phase, Single Speed Motors 9

9

9

2.7 11

2.7.1

Three Phase, Two Speed Motors

Motor Starting Methods

Thermal Wheel

Filters

Spare Filters 11

2.7.2 Panel & Bag Filters with

Side Withdrawal 11

2.7.3 Panel & bag Filters with

Front Withdrawal 11

2.8 Control Dampers 11

2.9 Final Inspection 11

3.0 COMMISSIONING 12

3.1 Commissioning Checklist 12

3.2 Fan and Motor 12

3.3 V-Belt Drives 12

Section Content Page number

4.0 MAINTENANCE 12

4.1 Fans 12

4.1.1 General Fan Maintenance 12

4.1.2 Belt Driven Fans 13

4.1.3 Belt Tensioning 13

4.1.4 Alignment 13

4.2 Bearings 14

4.3 Rotation 14

4.4 Filters 14

4.5 Humidifiers 14

4.6 Coils 14

Water 14

DX 14

Gas Burner 14

4.7 Heat Exchangers 14

4.8 Legionella check 14

4.9 Electric Heaters 14

4.10 Bulkhead Lights 15

4.11 Specialised Equipment 15

4.12 Maintenance Schedule 15

Routine Maintenance 15

Every 3 Months 15

Every 6 Months 15

Annually 15

4.13 Warranty 15

4.14 Spares 15

4.15 Service Enquiries 15

4.16 Service Chart 16

4.17 Certification 17

3 09. 05. 17. Leaflet Number 671506


82.5.4.2

2.6 10

4

To ensure that no roof damage occurs (in units fitted with a roof) the additional timber packaging

must be used.

To ensure that the delivery vehicle is loaded according to theplanned method of offloading,

Nuaire should be notified, to ensure coordination.

NOTE: When offloading, care must be taken to ensure that the AHU is kept level at all times

(unless specified by Nuaire).

All double deck sections leave Nuaire fully assembled, wherepossible. For more information on unit delivery please

call 029 2085 8585.

1.0 INTRODUCTION

1.1 Offloading

The weight of the unit modules and palletised items are displayed onthe packaging.

Some of the modules have an uneven weight distribution, and thiswill be indicated by labelling where appropriate.

Offloading and positioning of the equipment is the responsibility ofthe purchaser. Items should only be lifted by competent personnelfollowing appropriate risk assessment.

Spreaders should be used when lifting with slings to avoid damage tothe casings. Care must be taken to ensure that slings are correctlypositioned to avoid crushing and twisting of the unit castings. Careshould be taken to ensure the units remain upright and level at alltimes.

Where channels and/or support frames are bolted to the underside ofthe unit casing, slings or fork-lift arms should be positioned in thebase frame lifting apertures, full details of which are in the followingsection.

If Lifting lugs / eyes have been supplied / or fitted it is recommendedthat they are used.

09. 05. 17. Leaflet Number 671506


Fig. 1: Typical Methods of lifting.

Assembly withbase frame.

Palletised. Forklift. Slings via spreaders fitted tounit with base frame.

For Base Frame Lifting Points (see 1.2 page 5)

Please refer to figure 2.

Please note that above images are examples of typical lifting methods. Actual unit lifting plan and risks must be assessed by competent personnel before moving the unit.

1.0 INTRODUCTION cont.

1.2 Base Frame Lifting Points

When units are constructed of multiple modules each module willhave it's own individual base frame, which is then connected to thenext to assemble the full system.

All base frame sections will have 50mm square lifting holes at theend of each side to enable lifting. In addition to this, covered forklifting channels are located across the width of the base frame, if themodule length is sufficient to allow this. For shorter modules the forklifting points will be along the length of the section, without acovered channel. Please refer to figure 2.


5 09. 05. 17. Leaflet Number 671506

1.3 Unit Protection

Unless otherwise specified, unit sections will be delivered to sitecovered in “shrink wrap” polythene, which should provide a morethan adequate level of protection against inclement weather.

Should alternative methods of unit protection be required (i.e. timber, Corex, or flame retardant materials), Nuaire Limitedshould be notified of the specific requirements at the pre- contractstage. Waste must be disposed of by a registered waste carrier inaccordance to national regulations.

1.4 Unit Storage

The equipment must be stored in a dry, internal location. Ductworkconnection apertures should be sealed against the ingress of dust,

water and vermin. Note that units that are intended for externallocations are generally not fully weatherproofed until theirinstallation, including ductwork connections, is complete.

If the storage period is to exceed two months, contact Nuaire forguidance on the appropriate ‘mothballing’ procedures. Do not stackunits, modules or components that are not designed to be stacked.

1.5 LubricationMotors are fitted with ‘sealed for life’ bearings and do not requireany lubrication. All dampers should be rotated and lubricated asnecessary.

Fig. 2: Base Frame Detail.

Section length Section lengthSection length

Sect

ion

wid

th

50.0

50.0

50.0

50.0

50.0

100.

0100.0

100.0

Overall unit length

76, 100, 150 or 200

CENTRE SUPPORT CAN BE ON EITHER SIDE OF CENTRE LINE

A (1:5)

50mm x 50mm Lifting hole

50.0

50.0

A

Sufficient clearance for U-traps on condensate drain andoverflow connections should also be considered by the

purchaser.

2.0 INSTALLATIONInstallation must be carried out by competent personnel, inaccordance with good industry practice, with the appropriateauthority and in conformance with all statutory and governingregulations.

The unit should stand upright and level on the floor, foundation orsupporting steelwork which should be rigid, flat and level and shouldbe capable of supporting the weight of the unit including water orrefrigerant in the coils.

Nuaire Limited takes no responsibility for the coordination ofsupport.

2.1 Location

To prevent possible reintroduction of contaminated air through theoutside air intake, the unit should be located away from building fluestacks or exhaust ventilators.

Once assembled and in position, sufficient free space must beavailable adjacent to the unit for future inspection, maintenance,component service, repair and replacement and connection ofservices.

It is recommended that at least the unit width (vertically arrangedunits); or half the overall unit width (horizontally arranged units) +100mm be allowed. (note – for units with a horizontal layout, accessis typically required to both sides of the unit casing).

2.2 Air Leakage

Loading, transportation, off loading and site positioning can cause theair handling unit structures to move, therefore panel seals will notalways remain fully intact.

It is inevitable that in such cases, re-sealing of the units panels andjoints may have to be carried out on site for the air-handling unitsto 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 leakagetest if the above have not been carried out correctly.

2.3 Unit 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 plateswith a single bolt hole provided to each corner through which thesections are bolted together. Unit access panels must be removed toperform the assembly operation. Plates will either have clearanceholes - or one face with a threaded insert and the other with aclearance hole.

In instances of restricted access to the internal corner bolts, externalclamps can be provided to facilitate external connection of modules.

A sealing gasket should be applied as necessary to the mating facesof the unit frames before bolting together.

Air leakage, air blow marks to the unit casings and unacceptablenoise levels could result if the correct installation procedures are notemployed.

Fig. 3: Cleat and bracket detail.

6 09. 05. 17. Leaflet Number 671506


Connection plate

Fixing rod

Pentapost frame

Inner panel skin

Panel infill

Outer panel skin

Optional external clamp

Fixing rod. Fixing rod / External clamp detail.

Optional external clamp.

2.4 Weather Resistant Units

Weather resistant units in multiple sections will have sectional roofcomponents that must be fitted and sealed after the unit sections arebolted together. All necessary nuts, bolts, washers and sealant aresupplied with each unit and are normally bagged and located withinthe fan section. Suitable mastic sealant is to be provided by others.

The equipment must not be exposed to the weather in anunassembled or partially assembled state. All ductwork, sealing andassembly work must be completed before the unit can be consideredweather resistant.

Where the weatherproof roof assembly of two sections meet, aweatherproof cover strip must be applied to seal the seam, this willbe supplied with the unit.

Fig. 4: Weather resistant roof components.

2.5 Connections

2.5.1 Ductwork

Nuaire do not provide ductwork connections with units, instead theopen ended framework should be utilised. Spigots are available as anoption, refer to technical documents for information relatingspecifically to the manufactured unit.

2.5.2 Coils

When connecting coils, special care is needed to allow for expansionand 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 takento ensure that there are no vertical rising condense lines, unlesspumped.

2.5.3 PipeworkCare 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.

2.5.4.1 Condensate DrainHeat 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.

Provision may be required, and if so, should be made, for the fitting of a correctly sized cleanable trap to each drain connection.

Under Negative PressureIf 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 (see fig. 5a).

A = Fan inlet pressure (mm H2O) +25mm (minimum).Allow 100mm for these units if pressure is unknown.B = A/2. (minimum).(Note: 10Pa = 1mm H2O).

Under Positive PressureIf the condensate tray is located at the outlet side of the fan(i.e. under positive pressure) then calculate the values of A & Bas shown below).

A = 25mm (minimum).B = Fan outlet pressure (mm H2O) + 25mm (minimum).Allow 100mm for these units if pressure is unknown.

Fig. 5a: Condensate trap.

Above: Example of horizontal unit with weather kit.

Right: Example of stacked unit with weather kit.

Below: Roof assembly detail. Full assembly guide available uponrequest.

7 09. 05. 17. Leaflet Number 671506


If a frost coil is not fitted then appropriate control methodsmust be taken to prevent the coils, filters and other

equipment from freezing. (by others)

Hand tight plug

B

A

From condensatedrain pan Hand tight plug

Connect to ventilated downpipe to drain

04. 08. 2016 Leaflet Number 671506


2.5.4.2 Condensate Connections – Plate Heat Exchanger

8

Where 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 (see fig. 5b).

Vertical plate heat exchangers have 2x 22mm drain connections. Connections are typically located at the bottom of the access side of the PHX module (see fig. 5c).

Figure 5c: Vertical plate heat exchanger condensate connections.

Figure 5b: Horizontal plate heat exchanger condensate connections.

1 x 22mm Condensate connection

2 x 22mm Condensate connections

1 x 22mm Condensate connection

Side View

End View

Access Side View

End of Page

9 09. 05. 17. Leaflet Number 671506


2.5.5 Electrical

Care should be taken to ensure that the rotation of three phasemotors correspond with the direction shown on the frame.

All electrical connections to the fan are to be made using flexiblecable and containment materials to allow for fan belt adjustment andthe movement of anti-vibration mounts.

Ensure suitable earth bonding is maintained on all AHU sections.

2.5.6 Motor Wiring Diagrams

Fig. 6: Typical Three Phase, Single Speed Motors.

Fig. 7: Typical Three Phase, Two Speed Motors.

Motor Starting Methods

Motor Power DOL Star/Delta InverterRange

0.18 to 3 kW Star N/A Star

4 to 5.5 kW Delta N/A Delta

7.5 to 90 kW N/A Star/Delta Delta

Recommended tightening torqueM5 = 4Nm, M6 = 7Nm and M10 = 14Nm

W1 W2

V2

U2U1

V1

L1

L2

L3

Cables enter from left

Cables enter from right

W1

W2 V2

U2

V1

L1

L2L3

U1W1 W2

V2

U2U1

V1

L1

L2

L3


W1 W2

V2

U2U1

V1

L1

L2

L3

Cables enter from left

W1 W2

V2

U2U1

V1

L1

L2

L3



W2

W1 V1

U1

V2

L1

L2L3

U2

Cables enter from the leftor the right

W2

W1

V1

U1

V2

L1

L2L3

U2

1W 2W

2V

2U1U

1V

L1

L2

L3

Low speed

High speed

2V

2U

L1

L2L3

1W 2W

2V

2U1U

1V

L1

L2

L3

High speed

1W 2W

2V

2U1U

1V

L1

L2

L3

Low speed

1W 2W

2V

2U1U

1V

L1

L2

L3

High speed

Low speed

1W 1V

1U

L1

L2L3

1W 2W

2V

2U1U

1V

L1

L2

L3

Low speed

1W 2W

2V

2U1U

1V

L1

L2

L3

High speed

1W 2W

2V

2U1U

1V

L1

L2

L3

Low speed

1W 2W

2V

2U1U

1V

L1

L2

L3

High speed

2W

Low speed

1W

1U

L1

L2L3

1V

High speed

2W

2U

L1

L2L3

2V

Low speed

1W

1U

L1

L2L3

1V

High speed

2W

2U

L1

L2L3

2V

2U 2W

2V

1U 1W

1V

Low speed

1W 1V

1U

L1

L2L3

High speed

2W

2U

L1

L2L3

2V

1U 1W

1V

Two separate windings r/r

Two separate windings Y/Y

Dahlander connection r/YY

Dahlander connection Y/YY

Y Connection

r Connection

04. 08. 2016 Leaflet Number 671506


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1

2

3

4

5

6

8

9

10

11

12

13

14

15

16

17

18

19

B1

10k +10 V reference voltageAnalogue setpoint inputGND (analogue)Analogue output+15 V (max. 100 mA)Start clockwiseExternal SensorPriority SpeedParameter set switchingReleaseGND (digital)Relay output 1 (normally open contact)Relay output 1 (changeover contact)Relay output 1 (normally closed contact)PTC motor temperature monitoringPTC motor temperature monitoring

Relay output 2 (normally open contact)Relay output 2 (changeover contact)Relay output 2 (normally closed contact)

Terminal Description

1, 2, 3 Connection of control signal

5, 7, 11 Connection of inductive sensor for speed monitoring

6 Start of wheel (terminal 10 must be under power)

9 not under power Sorption wheel operating mode

9 under power Condensation/enthalpy wheel operating mode

10 Reset-function by short tem voltage cut-off, acknowl-edgement of faults

15, 16 Connection of thermal contact from motor

17, 18, 19 Potential-free output for for output of faults via relay

R/370 R/750

Output Motor-side

Max. motor power kW 0.37 0.75

Nominal output current A 2.2 4

Max. output voltage V 3 x 230 3 x 230

Output frequency Hz 0…500 0…500

Mains input

Rated voltage V 230 230

Mains frequency Hz 50/60 50/60

Fuses A T 6 8

Genera data

Protection rating IP54 IP54

Ambient temperature

°C 0…40 0…40

Air humidity % 20…90 20…90

Power dissipation W 35 45

Wheel Diameter mm up to 2620 up to 3000

Dimensions H x W x D mm 282 x 112 x 70 282 x 112 x 70

2.6 Thermal Wheel (If Applicable)The thermal wheel incorporates a purge section and is fitted with a rota-tional 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 undervoltage, overvoltage or non-ap-proved converter temperature.

Figure 8: Wiring diagram - Thermal Wheel Control Unit

Technical Data for Control Units

Control Inputs for Thermal Wheel Control Units

10

2.8 FiltersFilters will be provided in banks on suitable slide rails, so that they can be withdrawn.

Magnahelic gauges are available as optional extras.

2.8.1 Spare filtersIf 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.

2.8.2 Panel and Bag Filters with side withdrawalInsert the filters by sliding them into the railing provided. If specified, blanking filters are fitted at the end of the railing.

Fig. 10a: Typical panel filters with side withdrawal.

2.8.3 Panel and Bag Filters with front withdrawalInsert filters squarely into the frames and retain using retaining P-clips.

Fig. 10b: Typical panel filters with front withdrawal.

Fig. 10c: Typical bag filters with front withdrawal.

2.9 Control DampersCare 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.

2.10 Final Inspection• Thoroughly inspect the unit after installation is complete.

• The inside of the unit should be checked; any objects whichmay have been left should be cleared.

• Check fan impellors, scrolls and outlets.

• Remove any transit protection fittings that may be attachedto the fan or motor base frame, and that all traps are primed.

• Close all access door seals for damage, and replace any panelsthat have been removed.

11 09. 05. 17. Leaflet Number 671506


Capping strip

2.7 Bulkhead Lights (If Applicable)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.

Fig. 9: Bulkhead light wiring diagram.

COM

1 2

EARTHING LOOP

N L

L

N

EARTHFROMLIGHT

TO INTERNAL

LIGHT

Key:Internal Factory ConnectionCustomer Connection

EMains230V50Hz

12 09. 05. 17. Leaflet Number 671506


3.0 COMMISSIONINGBefore commissioning the unit, ensure that all equipment has beenassembled in accordance with the installation procedure all instanceswhere the unit is in operation the access doors should remain closed;at no time, during maintenance or otherwise, should anyone be insidea unit whilst it is in operation.

3.1 Commissioning Checklist 4

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.

Fan and motor pulleys are aligned.

Anti-vibration mounts are adjusted accordingly.

Check fan belt tension.

Rotate fan impellors 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.

3.2 Fan and Motor

Care should be taken to ensure that the fan and motor run freely andthat the fan is rotating in the correct direction.

The electrical current being drawn by motors should not exceed themanufacturers recommendations (specified on the motor plate). Ifthe current exceeds this, check the fan volume flow rate and thestatic resistance.Inverter should be calibrated to match the design and runningfrequency that is provided on the datasheet of each specific unit.

3.3 V-Belt Drivers

Ensure the alignments of pulleys are correct and make any necessaryadjustments. It is important that any residue oil or grease from thepulleys or belts is cleaned. Belts should then be tensioned in accordance to the manufacturers’recommendations. (See the Maintenance section for further detail).

4.0 MAINTENANCEIt is the owner’s responsibility to ensure that the air handlingequipment is maintained accordingly. In doing so, regular andscheduled checks will decrease the possibility of unforeseen andpossibly costly repairs. Maintenance tasks should be taken care of bya competent person, if system failure occurs due to impropermaintenance, Nuaire will not be held liable for the costs of restoringa unit to its previous working condition. For unit maintenance, please call Nuaire.

4.1 Fans

Please refer to general arrangement drawings for details of the typeof fan and drive that is fitted. Maintenance guidelines for all fans arebeyond 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 impellor is at rest.

• Measures are taken to ensure that the accidental, uncontrolled running of the fan is prevented duringmaintenance work.

In general, fans should be inspected twice a year, and care should betaken to ensure that any unusual vibration or sound is investigated asan urgent matter.

Access to the fan section is via hinged or lift-off panels. Cable entrymust be made through the apertures provided. Screwed glands withcable restraint devices should be used.

4.1.1 General Fan Maintenance

• Access to the fan is normally gained by opening thehinged access doors, in some instances there will be aturn 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 careof this) Do not use a steam or any other high pressurecleaners.

• Inspect the connection between the fan and unit for anydamage or wear and tear.

• In accordance with BSEN1886:2007 access doors to the fanmodules are lockable. As such, it must be ensured that apadlock is used to prevent access when fan is in operation, orcoming to rest (padlock supplied by others).

4.1.2 Belt Driven FansIf there is a belt driven fan, ensure that the motor and fan pulleys are aligned. V belt drives should be checked for wear and tear, and that the tension complies with the motor manufacturers’ guidelines(contact Nuaire for specific literature).

Any replacement belts should be the same spec and length as the ones originally supplied (for details, please refer to the manufacturers literature).

4.1.3 Belt TensioningTo check the correct tension of a belt drive, 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. Check this force with the tensioning forces table.

Fig. 11: Adjusting the drive belts.

Tensioning Forces Table

4.1.4 AlignmentGood alignment of pulleys is important. Poor alignment will result in belt flank wear.

Fig. 12: Alignment examples.

13 09. 05. 17. Leaflet Number 671506


Force required to deflect belt 16mm per metre of span.

Belt Small pulley Newton KilogramSection dia. (mm) (N) force (Kgf)

SPZ 56 to 95 13 to 20 1.3 to 2.0100 to 140 20 to 25 2.0 to 2.5

SPA 80 to 132 25 to 35 2.5 to 3.6140 to 200 35 to 45 3.6 to 4.6

SPB 112 to 224 45 to 65 4.6 to 6.6236 to 315 65 to 85 6.6 to 8.7

SPC 224 to 355 85 to 115 8.7 to 11.7375 to 560 115 to 150 11.7 to 15.3

Z 56 to 100 5 to 7.5 0.5 to 0.8

A 80 to 140 10 to 15 1.0 to 1.5

B 125 to 200 20 to 30 2.0 to 3.1

C 200 to 400 40 to 60 4.1 to 6.1

Correct (left)Pulleys are correctly aligned. Shafts are paralleland in the same plane.

Angled (below)Shafts are not in the sameplane.

Angled (left)Shafts are not parallel.Corrected by resettingshafts parallel. Ensure nodeflection is taking placein supporting frameworkor shafts.

Offset (left)Pulleys are offset.Corrected by movingeither pulley along theshaft until aligned.

A new drive should be tensioned at a higher value to allow for thenormal drop in tension during the running period. When the drivehas been running for a few hours, tension should be rechecked &

adjusted to the higher value.

Care should be taken to tension the drive at regular maintenanceintervals. A belt tensioning indicator can be purchased to ensure

accuracy.

If the unit contains a thermal wheel heat exchanger, pleaseensure that the rotation sensor is aligned with the sensing

studs, as this can become misaligned duringtransport/installation thus causing a fault signal.

Isolation - Before commencing work make sure that the unit is electrically isolated from

the mains unit and sufficient time has passed to allow thefans to run down (5 minutes minimum).

4.2 Bearings

The bearings that are fitted will be (unless otherwise specified)“sealed for life”, therefore consequence maintenance is not required.

Fan bearings are lifelong; up to 40,000 hours of operation. In cases of heavy duty operation, maintenance intervals are to be established by the operator.

4.3 Rotation

Ensure that the directions of rotation of the driving motor arechecked and operating correctly.

4.4 Filters

When removing the filter access panels, pay attention to the airflowdirection marked on the panel, this must be replaced to the exactposition prior to being removed. Disposable filters should be checked,and changed when they become fully laden with dust. Washablefilters should be removed and washed in a mild detergent, flushedwith clean water and allowed to dry before refitting.

4.5 Humidifiers

Any areas of corrosion should be identified and repaired, anysediment from the drain tray and connections should also remainclean.

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 thecorrect volume of water and is in smooth and quiet operation. Thepump 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 notoverheating.

4.6 Coils

Water

Water coils should be connected to ensure that full counter flowexists i.e. - the entering airflow meets the return connection. All water coils should be connected with the flow at the bottom andthe return at the top unless otherwise advised. Drain and bleed valvesare 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 airconditions to avoid coil freezing. Ideally, where the system is at risk offrost damage, the addition of a proprietary antifreeze solution to thewater is recommended.

Pipe-work connections should be made to the unit using appropriatetechniques, and must be independently supported. The connectionsshould be pressure tested.

DX

Direct expansion coils must be fitted with a correctly sizedthermostatic expansion valve with an external equalising connection.

The expansion valve phial must be fitted between the suction headerconnection and the equalising line. The recommendations of the TEvalve manufacturer should be referred to when locating the phial andadjusting the superheat. In all cases, settings should be in accordancewith the recommendations of the manufacturer of the refrigerationequipment.

All cooling coil drains must be connected to the sloping drain with acorrectly sized trap running to an open tundish or similar.

Gas Burner

If a gas burner is intended to be used with low air on temperatureplease discuss with Nuaire prior to order placement to ensure asuitable component selection.

4.7 Heat Exchangers

The recuperator block is normally protected from dust andcontamination by upstream pre-filters. It is possible to clean the unitwith compressed air in the case of dust deposits or by spraying with amild detergent solution for grease deposits.

Solvents, strong alkaline, acidic or any products that may beaggressive to aluminium or plastics should not be used. Do not usecleaning water over 50 deg C.

Drain lines should be checked to ensure that they are unobstructedand free draining. Traps should be checked that they are fully primedand functioning.

Drain pans should be flushed out periodically to removecontamination, and chemical treatments may be used to provideprotection between service visits.

4.8 Legionella CheckLegionella 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.

4.9 Electric HeatersAn 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 – to allow elements to cool on shutdown.

14 09. 05. 17. Leaflet Number 671506


15 09. 05. 17. Leaflet Number 671506


4.10 Bulkhead Lights

Ensure that lights are switched off and isolated before checking orchanging the lamp.

4.11 Specialist Equipment

Contact Nuaire for maintenance of specialised equipment that wouldhave been specified during design stage. A breakdown of thecomponent parts can be found on the design specificationdocuments, additional maintenance literature is available, pleasecontact Nuaire. This applies to any components not specificallymentioned in this document.

4.12 Maintenance Schedule

It is important that maintenance checks are recorded and that theschedule is always adhered to, in all cases, the previous report shouldbe referred to.

Particular attention to the items mentioned below should beconsidered:

• Routine Maintenance.

• Any areas of corrosion should be treated and all areasof the unit should be cleaned.

• Any drain trays should be cleaned and repaired ifnecessary.

• Check all access doors for leakage and if necessary, locks should be adjusted and any replacement gasketmaterials should be replaced as required.

Every 3 months

• Check filters and change/clean if required.

• Check fin coil banks and heat exchangers. If necessaryclean with a soft brush or vacuum. Also check forsigns of contamination.

• Check fan belt tensions and pulley/belt wear.

• Ensure condensate drains are cleaned clear and thatwater can flow feely from unit.

• Clean unit casting and ensure that any corrosion isaddressed by treating.

• Filter magnahelic gauges should be checked andtopped up with fluid.

Every 6 Months

• Ensure all locks and hinges are lubricated andadjusted as required.

• Check control dampers blades.

• Check operation of damper actuators and linkagesand adjust as necessary.

Annually

• All electrical terminals within the unit should betightened.

• Coil faces should be inspected and any dust removed.

• Thoroughly inspect the unit and its components forerosion, acting immediately to treat/restore anydamaged areas.

• Check all earth connections.

4.13 Warranty

BOXER has a 12 months parts and labour warranty.

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.

4.14 After SalesFor technical assistance or further product information, including spare parts and replacement components, please contact the After Sales Department.

Telephone 02920 858 400 [email protected]

16 09. 05. 17. Leaflet Number 671506


4.16 Service Chart

3 Month/9 Month Service 6 Month Service 12 Month Service

Symbol Action Date Action Date Action DateInitials Initials Initials

Damper Air recirculation section.Air recirculation section.

Check the damperperformance.

Check the damperperformance.

Clean the damper.Check the damperperformance.

Filter. Check the pressuredrop and change thefilter if necessary.

Check the pressuredrop and change thefilter if necessary.

Check the pressure dropand change the filter ifnecessary.

Rotary heat exchanger.

General inspection.Check the seals.

Clean the rotor. Clean the rotor. Check the monitoringand purging equipment.

Plate heat exchanger.

General inspection.Check the damperperformance.

Clean the heatexchanger unit.

Clean the heatexchanger unit, damperand casing.

Heat-pipe exchanger.

General inspection.Check the damperperformance.

Clean the finned unit. Clean the finned unit,damper, drain tray andcasing.

Air heaters.Air coolers.Pipework package.

General inspection. Clean the finned unitand the electric heaterelements.

Clean the finned unit,electric heaterelements, drain tray &casing. Inspect thepipework package.

Humidifier Inspect the:Casing,Humidifier fills,Droplet eliminator,Water filter,Water tray,Spray pipes,Water trap,Water quality,Water flow andConstant-flow valve.

Clean the fan impeller,casing, unit casing.Check the bearings.

Check the belttension.

Check the belttension.

General inspection.Fans General inspection.

General inspection.Belt drive

Casing Check that the doorsare tight. Clean theinside if necessary.

3

9

3

9

3

9

3

9

3

9

3

9

3

9

3

9

3

9

IHUMID

Inspect the:Casing,Humidifier fills,Droplet eliminator,Water filter,Water tray,Spray pipes andWater flow.

Inspect the:Casing,Humidifier fills,Droplet eliminator,Water filter,Water tray,Spray pipes,Water trap,Water flow andConstant-flow valve.

17 09. 05. 17. Leaflet Number 671506

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 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 electricallylive 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 documentation.

7.0 OPERATIONAL REQUIREMENTS

7.1 Equipment access panels must be in place at all times during operation of the unit, and must be secured with the original fastenings.

7.2 If failure of the equipment occurs or is suspected then it should be taken out of service until a competent person can effect repair or examination. (Note that certain ranges of equipment are designed to detect and compensate for fan failure).

8.0 MAINTENANCE REQUIREMENTS

8.1 Specific maintenance requirements are given in the relevant product documentation.

8.2 It is important that the correct tools are used for the various tasks required.

8.3 If the access panels are to be removed for any reason the electrical supply to the unit must be isolated.

8.4 A minium period of two minutes should be allowed after electrical disconnection before access panels are removed. This will allow the impeller to come to rest.

NB: Care should still be taken however since airflow generated at some other point in the system can cause the impeller to “windmill” even when power is not present.

8.5 Care should be taken when removing and storing access panels in windy conditions.

INFORMATION FOR SAFE INSTALLATION, OPERATION AND MAINTENANCE OF NUAIRE VENTILATION EQUIPMENT

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.

4.17 Certification


DECLARATION OF INCORPORATION AND INFORMATION FOR SAFE INSTALLATION, OPERATION AND MAINTENANCE

We declare that the machinery named below is intended to be assembled withother components to constitute a system of machinery. All parts except for moving parts requiring the correct installation of safety guards complywith the essential requirements of the Machinery Directive. The machinery shallnot 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, EN60204-1, BS EN ISO 9001, BS EN ISO 13857

Applied National Standards: BS848 Parts 1, 2.2 and 5

Note: All standards used were current and valid at the date of signature.

Signature of manufacture representatives:Name: Position: Date:

1) C. Biggs Technical Director 26. 01. 11

2) A. Jones Manufacturing Director 26. 01. 11

Documents

BESPOKE BOXER AIR HANDLING UNITS Installation and ...nuaire.info/IandM/671506.pdf · AIR HANDLING UNITS Installation and Maintenance Instructions ... 1.4 Unit Storage The equipment