FläktGroup Air Curtains Operating instructions

OPERATING MANUAL

AIR CURTAINS

1 AC

2 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

FläktGroup Product Range

Air curtains 1

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 3

Model code

Product range

ACL

ACC

ACDF

ACF

=

Linea

Comfort

Direct Flow

Comfort Flat

Series:

for door heights*

M

=

3.0 - 3.3 m

G

=

3.5 - 3.8 m

B

=

4.0 - 4.5 m

BB

=

5.0 - 5.5 m

Series:

for door widths*

10

=

1.0 m

15

=

1.5 m

20

=

2.0 m

25

=

2.5 m

30

=

3.0 m

Heat exchanger

A

=

Without heat exchanger

E

=

Electrical heating

W

H

L

=

Water heat exchanger

Temperatures between

60 and 80°C

Water heat exchanger

High temperatures

>80°C

Water heat exchanger

Low temperatures <60°C

Fan

_ _

=

AC-motor

EC

=

EC-motor

Country code

I

=

Made in Italy

* Installation height depends on project requirements

.

-

AC…

M

10

A

EC

I

Table of Contents AC

4 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

Model code .............................................................................................. 3

1 Safety and user instructions ......................................................... 6

1.1 Availability of the operation manual .............................................................. 6

1.2 Scope of the operation manual ..................................................................... 6

1.3 Symbols used ................................................................................................ 6

1.4 Safety instructions: warning and danger symbols ......................................... 7

1.4.1 DANGER – Death/serious irreversible injury ................................... 7

1.4.2 WARNING – Death/serious injury .................................................... 7

1.4.3 CAUTION – Minor or moderate injury .............................................. 8

1.4.4 ATTENTION – Environmental or material damage .......................... 8

1.5 Identification of safety information ................................................................. 9

1.6 Safety-conscious work procedures ............................................................. 10

1.7 Proper use ................................................................................................... 11

1.8 Improper use ............................................................................................... 11

1.9 Safety regulations and codes ...................................................................... 12

1.10 Modifications and changes .......................................................................... 12

1.11 Spare parts .................................................................................................. 12

1.12 Selection and qualification of personnel...................................................... 12

2 Technical data .............................................................................. 13

2.1 Material specification ................................................................................... 13

2.2 Functional principle of air curtains ............................................................... 14

2.3 Description of air curtain ............................................................................. 14

2.4 Operating limits ........................................................................................... 15

2.4.1 Sound levels ................................................................................... 15

2.5 Spare parts .................................................................................................. 15

3 Shipping and storage ................................................................... 17

3.1 Transport safety .......................................................................................... 17

3.2 Packaged content ........................................................................................ 17

3.3 Packaging .................................................................................................... 17

3.4 Handling and shipping ................................................................................. 17

3.4.1 Handling of air curtains without casing ........................................... 18

3.5 Storage ........................................................................................................ 18

3.6 Disposal ....................................................................................................... 18

4 Assembly ...................................................................................... 19

4.1 Installation site ............................................................................................. 19

4.2 Assembly of air curtain ................................................................................ 19

4.3 Safety clearance .......................................................................................... 20

4.4 Wall installation ........................................................................................... 21

4.5 Ceiling installation ....................................................................................... 23

4.5.1 AC-Linea accessories for false ceiling installation ......................... 25

4.6 Vertical installation ...................................................................................... 27

5 Hydraulic connection ................................................................... 28

5.1 Valves .......................................................................................................... 29

5.1.1 3-way valve with actuator ON/OFF ................................................ 29

6 Electrical connection ................................................................... 30

6.1 On-site requirements ................................................................................... 30

Air curtains 1

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 5

6.1.1 Electrical connection ...................................................................... 30

6.1.2 Connection to mains network ......................................................... 30

6.2 Connecting air curtain ................................................................................. 31

6.3 Air curtains with electric heating ................................................................. 32

6.3.1 Air curtain with electric heating - Electrical connection .................. 33

6.3.2 Air curtain with electrical heating wiring diagram - AC motors....... 34

6.3.3 Thermostat wiring diagram connection to R310E board ................ 39

6.3.4 R310E operating mode .................................................................. 40

6.3.5 Protection against overheating ...................................................... 40

6.4 Ambient air curtains and air curtains with water heater .............................. 41

6.4.1 Ambient and Water Air curtain - Electrical connection ................... 41

6.4.2 Ambient and Water air curtain wiring diagram - AC motors ........... 43

6.4.3 Ambient and Water air curtain wiring diagram - EC motors ........... 44

6.4.4 Thermostat and Valve actuator wiring diagram ............................. 47

6.4.5 R515 operating mode..................................................................... 48

7 Commissioning ............................................................................ 50

7.1 Initial commissioning ................................................................................... 50

7.2 Air venting of heat exchangers (water units) .............................................. 51

7.3 Check the valves (water units) .................................................................... 51

7.4 Setting the position of outlet........................................................................ 51

7.5 Air curtain with electric heating - operation ................................................. 52

7.5.1 Operation with control unit R310E ................................................. 52

7.6 Ambient air curtains and air curtains with water heater - operation............ 53

7.6.1 Operation with control unit R515 .................................................... 53

8 Maintenance .................................................................................. 55

8.1 Maintenance ............................................................................................... 55

8.2 Quarterly maintenance ................................................................................ 56

8.3 Semi-annual maintenance .......................................................................... 57

8.3.1 Check the fan ................................................................................. 57

8.3.2 Check heat exchanger ................................................................... 57

8.3.3 Check the screwed connection and valve connection ................... 58

8.3.4 Check electrical connections and earthing .................................... 59

8.4 Before cooling season ................................................................................ 59

8.4.1 Condensate tray cleaning .............................................................. 59

8.5 Before cooling and heating season ............................................................ 60

8.5.1 Venting heat exchanger ................................................................. 60

8.6 Troubleshooting .......................................................................................... 61

9 Dismantling and disposal ............................................................ 63

9.1 Dismantling ................................................................................................. 63

9.2 Disposal ...................................................................................................... 63

Original operation manual – Copyright note

Disclosing, copying, distributing or taking any action in reliance on the contents of this document is strictly prohibited without express prior consent.

Violations entail liability for any damages or other liability arising. All rights in relation to patents, utility patents or design patents are reserved.

6 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

1 Safety and user instructions

This is an original operation manual verified by the manufacturer.

AC air curtains are developed and manufactured according to the state-of-the- art

technological standards, established technical safety codes and EC Directive on

Machinery.

AC air curtains ensure maximum operational safety and meet the highest quality

standards. Future-oriented technology and pronounced operator and maintenance

friendliness were combined in this product series.

However, every air curtain unit can pose an unavoidable residual risk of injury or risk

of equipment or other property. Therefore, your personal safety and the proper

operation of the unit depend on the strict observance of the safety instructions.

Failure to follow the safety precautions could result in death, serious injury,

environmental damage and/or considerable property damage.

Observing the safety instructions in the current operation manual will help avoid the

risks, ensure economical operation of the unit and let you enjoy the full benefits of

the product.

The safety aspects covered by this chapter are valid for the entire operation manual.

1.1 Availability of the operation manual

This operation manual contains important instructions regarding safe and proper

operation of the air curtain.

This operation manual applies to installation companies, operators, building

technicians, technical personnel or instructed persons as well as electricians.

This manual as well as the safety information of the manufacturer of the individual

components must always be available at the unit's installation site. When working on

the equipment, observe all instructions and precautions in the current operation

manual, in particular the chapter on safety.

1.2 Scope of the operation manual

This operation manual provides information about the following:

- Transport

- Assembly

- Installation

- Electrical installation

- Commissioning

- Operation

- Maintenance, cleaning and disposal

1.3 Symbols used

The following symbols are used to highlight particular text sections in this operation

manual:

- This symbol is used to indicate lists.

• This symbol indicates handling instructions.

 This symbol indicates the result of an action.

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 7

User instructions!

User instructions provide optimal, efficient and environmentally friendly methods for

using and handling the units.

Recycling!

This symbol is used to highlight instructions for the recycling of packaging material

and disused unit components, which must be separated depending on the material

type (e.g. metal, plastic, etc.).

1.4 Safety instructions: warning and danger symbols

1.4.1 DANGER – Death/serious irreversible injury

DANGER

Indicates a hazardous situation which would result in death or serious irreversible

injury if the safety instructions are not followed.

Example:

DANGER

Electrocution through hazardous voltage will lead to death or serious injury!

• Disconnect the unit from the power supply and ensure the power cannot be

switched back on.

• Ensure the unit is voltage-free and isolated, ground and short circuit the unit,

cover or shield off neighboring live components.

1.4.2 WARNING – Death/serious injury

WARNING

Indicates a hazardous situation which can result in death or serious irreversible

injury if the safety instructions are not followed.

Example:

WARNING

Risk of rotating components!

• Risk of accidents due to rotating fan impellers.

• Disconnect the device from the power supply before starting any work.

• Make sure that the device is secured against being switched on again.

8 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

1.4.3 CAUTION – Minor or moderate injury

CAUTION

Indicates a hazardous situation which can result in minor or moderate injury, if the

safety instruction is not followed.

Example:

CAUTION

Sharp edges can cause injuries!

There is a risk of cuts on thin edges when cleaning fins.

• Wear chemical resistant gloves.

1.4.4 ATTENTION – Environmental or material damage

ATTENTION

Indicates actions that can result in damage to equipment or property.

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 9

1.5 Identification of safety information

The following warnings are used:

Danger of electrical current!

This symbol indicates a risk of electrical shock that can result in serious injury,

death and material damage.

Risk of personal injury!

This symbol indicates a hazardous location with a risk of personal injury including

death and material damage.

Danger due to overhead loads!

This symbol indicates a hazardous suspended load with a risk of personal injury

including death and material damage.

Risk of accident due to hot medium!

This section specifies procedures and precautions for preventing personal injury

resulting from contact with a hot medium.

Sharp cutting edges!

This section specifies procedures and precautions for preventing personal injury

resulting from cuts caused by sheet metal.

Caution due to rotating components!

This symbol indicates a hazardous location with a risk of personal injury including

death and material damage.

Environmental damage!

This symbol warns about possible damage to the environment.

Danger of scalding!

This symbol indicates a risk of scalding from leaking hot liquids that can result in

personal injury, including death and material damage.

Damage to the air curtain!

This symbol indicates a hazardous location with a risk of material damage that can

also lead to personal injury.

10 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

1.6 Safety-conscious work procedures

Observe the following instructions when carrying out installation, adjustment or repair

jobs:

• Wear suitable protective clothing during work, such as protective footwear,

gloves, safety goggles, etc.

• Avoid flame sources, especially burning cigarettes. Open flame sources and

smoking in the proximity of the unit are prohibited.

When working within range of mains voltage:

DANGER

Electrocution through hazardous voltage will lead to death or serious injury.

• Disconnect the air curtain from the power supply and ensure the power cannot

be switched back on.

• Ensure the air curtain is voltage-free and isolated, ground and short circuit the

unit, cover or shield off neighboring live components.

For all kinds of work:

WARNING

Danger of scalding!

Before performing work on the valves or the inlet or outlet pipes, shut off the

heating medium inlet to prevent scalding. Only start work after the heating medium

has cooled down.

•

Use suitable protective equipment for all work.

CAUTION

Sharp cutting edges!

Special care must be taken during cleaning because of the risk of cutting injuries

due to thin and sharp edges.

• Wear chemical resistant gloves.

CAUTION

Caution due to rotating components!

Risk of accidents due to rotating fan impellers. Disconnect the unit from the power

supply before starting any work. Make sure that the air curtain is secured against

being switched on again.

CAUTION

Risk of personal injury!

Always wear protective gloves when shipping or installing the unit to prevent injury

caused by sharp edges.

Observe all applicable standards and work safety regulations.

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 11

ATTENTION

Environmental damage!

Do not pollute the environment with coolants and oils. Dispose of them in

accordance with local regulations and in an ecological manner.

1.7 Proper use

Air curtains are used in all commercial applications (shops, offices, shopping centres

and hotels), i.e. in normal ambient conditions according to the EN 60721-3-3:2019

and are exclusively designed for creating an air curtain that avoids unwanted heating

exchanges between inside and outside spaces. Water may be used as heating

medium.

Proper use also stipulates the observance of the operation manual as well as

adherence to all inspection and maintenance intervals specified by FläktGroup.

CAUTION

Damage to the air curtain!

During installation, the air curtain must be placed in such a way to prevent any

condensation or splash water penetrating into the electric equipment and causing

damage to the air curtain.

The following limit values apply to the medium for operating Cu/Al heat exchangers:

Parameter

Unit

Value

pH value (at 20 °C)

7.5 - 9

Conductivity (at 20 °C)

µS/cm

< 700

Oxygen content

O2

mg/l

< 0.1

Total hardness

°dH

1 - 15

Dissolved sulfur

S

not detectable

Sodium

Na+

mg/l

< 100

Iron

Fe2+, Fe3+

mg/l

< 0.1

Manganese

Mn2+

mg/l

< 0,05

Ammonium content

+

mg/l

< 0,1

Chloride

Cl-

mg/l

< 100

Sulfate

SO42-

mg/l

< 50

Nitrite

NO2-

mg/l

< 50

Nitrate

NO3-

mg/l

< 50

Tab. 1-1: Limit values for medium used in closed heating and cooling circuits

CAUTION

Damage to the air curtain!

In open systems (e.g. when using well water be sure to observe the limit values

from table Tab. 1-1), the water used should additionally be cleansed of suspended

matter using a filter to be installed at the inlet. Failure to do so could result in the

risk of erosion by suspended matter.

Also ensure that the unit is protected from dust and other substances that can

cause acidic or alkaline reactions with water (aluminum corrosion).

1.8 Improper use

The air curtain is used in an improper manner if it is applied for other purposes or a

purpose that is not covered by the previous chapter.

12 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

The manufacturer or supplier is not liable for any resulting damage; the user alone

bears the full risk.

The air curtain may not be operated:

- outdoors,

- in areas with explosion risk,

- in wet areas,

- in rooms with strong electromagnetic fields or

- in locations with high dust levels or aggressive air.

WARNING

Personal injury and equipment damage!

Improper use can cause personal injury and material damage.

1.9 Safety regulations and codes

When carrying out installation, commissioning, maintenance and service of the air

curtain, all local safety regulations and codes as well as generally established

technical practices must be followed.

1.10 Modifications and changes

It is not allowed to modify, add components or convert the air curtain in any way.

Changes or modifications to the unit will invalidate CE conformity and void warranty.

1.11 Spare parts

Only original FläktGroup spare parts are allowed, since FläktGroup is not liable if

third-party spare parts are used.

1.12 Selection and qualification of personnel

Note!

Ensure that every person working on the air curtains has read and understood the

entire operation manual.

Electrical and water connections must be carried out by qualified licensed staff or

other individuals with proper professional training and experience in the following

areas:

- Regulations concerning health and safety in the workplace

- Accident prevention regulations

- Guidelines and recognized codes for technical practice and engineering

All skilled staff must be able to assess the entrusted work and must be able to

recognize and avoid all associated dangers.

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 13

2 Technical data

Fig. 2-1: Air curtain AC-Linea

2.1 Material specification

Position

(Fig. 2-1)

Unit component

Material

1

Fan

Different materials

2

Inlet grille

Galvanized sheet metal

3

Heat exchanger or

Cu/Al

electrical heating rods

Different materials (Fe, Al)

4

Casing

Painted galvanized sheet metal

5

Outlet

Alu blades

6

Terminal box

Different materials

Tab. 2-1: Material specification

2

3

4

5

6

1

14 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

2.2 Functional principle of air curtains

Air curtains can significantly reduce energy losses by keeping the warm air in and

cold air out (or cold air in and warm air out during cooling seasons) with a door open.

Air curtains create an air barrier across a doorway and provide an effective seal

between two temperature zones.

Fig.

2-2: Functional principle of air curtain

2.3 Description of air curtain

Air curtains are available for door widths from 1 up to 3 m. Door heights (installation

height) are in four sizes (M=3 - 3.3 m; G=3.5 - 3.8 m; B=4 - 4.5 m; BB=5 - 5.5 m).

The air curtains have a basic construction of galvanized metal sheet. Fans are

controlled by three-speed (electrical heating) or five-speed transformers (water

heating), two or three-row Cu/Al heat exchangers (water heating) or electrical heating

rods. AL discharge grille is installed in this basic unit. The heat exchanger is made of

round copper pipes with aluminium fins, has lateral connections with a drain valve.

Adjustable air discharge grille is made of aluminium extrusion profiles.

Standard color is RAL9016, other RAL color is available as non-standard solution.

Suction

Air inside

Air outside

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 15

2.4 Operating limits

Note!

All other important information about unit capacity, weights, connections and sound

power is specified in the technical catalogue.

Operating temperature

5 °C to

+

40 °C

Ambient temperature

-10 °C to +40 °C

Max. operating pressure/temperature of heat

exchanger

1 MPa (10 bar) / 110 °C

Power supply

1 x 230 V~ 50 Hz (for ambient unit or unit

with water heat exchanger)

3x 400 V~ 50 Hz (for electrical heating)

Protection class of the fan (EN 60 529)

IP20 (B -

BB)

IP44 (M -

G)

Power consumption of the fan

See the type code

Tab. 2-2: Operating limits for air curtains

2.4.1 Sound levels

The sound levels of the air curtains are below 70 dB(A).

2.5 Spare parts

For the air curtains, the following accessories are available:

Description

Code

Description

Installation kit

ZDE

Galvanized sheet metal painted in RAL9016. mounting flush

with the ceiling

Installation kit

ZDS

Galvanized sheet metal painted in RAL9016. ceiling

installation with sliding support

Room thermostat

TERM

Wall suspension

WB (M - G) WBB (B - BB)

Galvanized sheet metal

Ceiling suspension

- door width 1.0 - 1.5 m

- door width 2.0 m

- door width 2.5 m

- door width 3.0 m

CS.4.M8

CS.6.M8

CS.6.M8 (M - G); CS.6.M10 (B - BB)

CS.6.M8 (M - G); CS.8.M10 (B - BB)

Antivibration mountings. threaded rods. bolts

Galvanized sheet metal

Controller

R515

Automatic 5-speed controller for water heating/cooling

3-way valve

- door height M and G

- door height B and BB

ZV4-MG ZV4-BB

With actuator ON/OFF

Mechanical door contact

DC.MEC

Magnetic door contact

DC.MAG

Stainless steel

condensate tray

DP

For cooling applications

Vertical installation kit

+V

For vertical installation

Tab. 2-3: Accessories

16 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

Note!

For all other important data on accessories refer to technical catalogue.

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 17

3 Shipping and storage

3.1 Transport safety

WARNING

Danger due to overhead loads!

It is extremely dangerous to stand under overhead loads.

• Make sure there are no persons below an overhead load!

ATTENTION

Damage to the air curtain!

Improper shipping can cause damage to the air curtain.

• If damage has been caused by impacts to the unit or by dropping it, carefully

check that the air curtain is working properly.

• Take care when transporting the air curtain!

3.2 Packaged content

Remove packing and inspect shipment immediately upon receipt to determine if any

damage has occurred to the unit during shipment (if any damage is found,

immediately file claim for damage with the transportation company), also check for

missing items and verify that the shipment is complete. For this purpose, compare

the details of the unit type plate with the information on the dispatch note.

The same applies to all accessory items. Missing parts or claims of shipping damage

can only be processed by the transport insurance if the damage has been confirmed

by the delivering carrier.

3.3 Packaging

AC air curtain is packed in a stretch foil on a wooden pallet.

3.4 Handling and shipping

WARNING

Danger due to overhead loads!

• Do not move the air curtain over people.

WARNING

Risk of personal injury!

Do not use any damaged lifting gear.

Transport only on pallets using a fork lift truck.

Secure load against tipping.

When using lifting and transport vehicles, use only technical aids with sufficient

loading capacity.

18 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

CAUTION

Sharp cutting edges!

Always wear protective gloves to prevent injury caused by sharp edges.

3.4.1 Handling of air curtains without casing

• When handling the air curtain basic unit, secure the unit on both unit sides (refer

to Fig. 3-1).

• Transport the unit with at least two persons in order to avoid injuries or damages,

or use relevant transport devices above a certain weight.

Fig.

3-1: Handling AC air curtain

3.5 Storage

Air curtains may only be stored in weather-protected rooms.

Note!

Permissible storage conditions: Air temperature: -10 °C to +40 °C

Air humidity: between 50 and 85% rel. humidity, no condensation

3.6 Disposal

Recycling

Ensure a safe and environmentally-friendly disposal of equipment and auxiliary

materials, packing materials and exchange parts. Use the local recycling facilities

and observe all pertinent local regulations and codes.

FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications 19

4 Assembly

DANGER

Danger of electrical current!

• Before making any holes in wall or ceiling, ensure there are no installed cables.

CAUTION

Risk of personal injury!

Some parts or sharp edges could cause the injury!

• Wear helmet, safety shoes and gloves during installation.

• Two persons are needed for installation.

4.1 Installation site

The type, features and ambient temperature of the installation site must be suitable

for the relevant air curtain. (Section 1.7 and 1.8).

Consider the following points:

- The support systems must be capable of bearing the weight of the unit, including

all accessories.

- Only indoor assembly of the unit is allowed.

Note!

Make sure all wall and ceiling openings are completed in coordination with an

architect or static engineer and the building contractor.

4.2 Assembly of air curtain

Assembly of air curtain needs to be realized according to project requirements and

instructions from this manual need to be considered.

Before installation the air curtain and accessories need to be checked for any

transport damage.

Note!

Please go through the instructions for proper installation as follows:

• Planners and customers are responsible for proper installation and operation of

air curtain and accessories.

• Air curtain must be controlled with R510 (water or ambient units) or R310E

(electrical units) controllers. Controllers are included. R515 controller can be

ordered as accessory for water units.

• There is thermal protection mounted in the winding of motors.

• Original FG suspension must be used for installation of air curtains.

Note!

Please consider the suction area must be clear for proper function of air curtain.

20 FläktGroup DC-2023-0449-GB 2023-05/R7 • Subject to modifications

CAUTION

Damage to the air curtain!

Ensure to install the air curtain without vibrations or tension.

Note!

Operation during construction work:

It is not allowed to operate the air curtains in dusty areas, especially during

construction work, e.g. when drilling or grinding concrete, floor grinding, separating

gypsum wallboards etc.

4.3 Safety clearance

WARNING

Risk of personal injury!

During the installation of the air curtain, a safety clearance to inflammable materials

must be ensured according to EN 13501-1+A1 (i.e. 150 mm for class A2 and

300 mm for classes B, C, D, E, F). There must be min. 1000 mm in the discharge

direction for all classes except A1.

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FläktGroup Air Curtains Operating instructions

FläktGroup Air Curtains Operating instructions

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