Berner ALC08-1036 Installation Manual
IMPORTANT INSTRUCTIONS
READ AND SAVE
THESE INSTRUCTIONS
Saving energy and creating healthy, comfortable environments
No. II-470
Date July, 2015
ARCHITECTURAL
Low Prole 8
FDA
RECOMMENDED
USDA
COMPLIANCE
AIR CURTAIN SERIES ALC08
Installation & Maintenance Instructions
TABLE OF CONTENTS
I. UNCRATING.......................................................................................................................................................................................................... 2
II. GENERAL MOUNTING INSTRUCTIONS ...........................................................................................................................................................2
III. WALL MOUNTING .............................................................................................................................................................................................2
IV. SUSPENDED MOUNTING ................................................................................................................................................................................ 3
V. ELECTRICAL CONNECTIONS ........................................................................................................................................................................ ....4
VI. FIELD CONNECTIONS ......................................................................................................................................................................................6
VII. OPERATION INSTRUCTIONS ......................................................................................................................................................................... 6
VIII. MAINTENANCE AND CLEANING ................................................................................................................................................................. 7
IX. SERVICE ............................................................................................................................................................................................................ 7
INTELLISWITCH®...................................................................................................................................................................................................10
QUICK START OPERATION.......................................................................................................................................................................... .10
FAQ’s (FREQUENTLY ASKED QUESTIONS)................................................................................................................................................ 12
THE INTELLISWITCH® PROGRAMMING)....................................................................................................................................................14
X. TROUBLESHOOTING........................................................................................................................................................................................19
XI. WARRANTY ......................................................................................................................................................................................................20
WARNING: TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK OR INJURY TO PERSONS, OBSERVE THE FOLLOWING:
A. Read all instructions before installing or using this air curtain.
B. Use this unit only in the manner intended by the manufacturer and described in this manual. Any other use not recommended by the
manufacturer may cause re, electric shock, or injury to persons. If you have any questions, contact the manufacturer.
C. Before servicing or cleaning unit, switch power o at service panel and lock the service disconnecting means to prevent power from
being switched on accidentally. When the service disconnecting means cannot be locked, securely fasten a prominent warning device,
such as a tag, to the service panel.
D. Installation work and electrical wiring must be done by qualied person(s) in accordance with all applicable national and local codes
having jurisdiction, including re-rated construction. See page 4, ELECTRICAL CONNECTIONS (NEC Code ANSI/NFPA No. 70).
E. When cutting or drilling into wall or ceiling, do not damage electrical wiring and other hidden utilities.
F. To reduce the risk of re, do not store or use gasoline or other ammable vapors and liquids in the vicinity of the air curtain.
G. This air curtain is hot when in use. To avoid burns, do not let bare skin touch hot surfaces. Keep combustible materials, such as furniture,
pillows, bedding, papers, clothes, etc. and curtains at least 1 inch from the top, back, front, sides and at least 6 feet from the discharge of
the air curtain.
H. Extreme caution is necessary when any air curtain is used by or near children or invalids, and whenever the heater is left operating
unattended.
I. Do not operate any air curtain after it malfunctions. Disconnect power at the service panel and have the air curtain inspected by a
reputable electrician before reusing.
J. To disconnect the air curtain, turn controls to "o", and turn o power to the air curtain circuit at main disconnect panel.
K. Do not insert or allow foreign objects to enter any ventilation or discharge opening as this may cause an electric shock or re, or damage
the air curtain.
L. To prevent a possible re, do not block the air intake or discharge of the air curtain in any manner.
M. The air curtain has hot and arcing or sparking parts inside. Do not use it in areas where gasoline, paint, or ammable vapors or liquids are
used or stored.
N. This heater may include an audible or visual alarm to warn that parts of the heater are getting excessively hot. If the alarm sounds (or
illuminates), immediately turn the heater o and inspect for any objects on or adjacent to the heater that may have blocked the airow or
otherwise caused high temperatures to have occurred. DO NOT OPERATE THE HEATER WITH THE ALARM SOUNDING (OR ILLUMINATING).
www.intelli-how2.com 800-245-4455 www.berner.com
I. UNCRATING
6’ minimum*
8’ maximum
20°
1" minimum
AIR
Discharge
Nozzle
1" minimum
side clearance
from combustible
material*
A
I
R
A
I
R
*Electrically Heated Units Only
INTERIOR
EXTERIOR
Carefully examine the carton(s) for damage. If the carton is
damaged, immediately notify the shipping company. Do not
delay in ling claim. If the air curtain(s) were shipped on
wooden skids, remove protective wood and banding straps securing the carton(s) to the skid. Open the carton(s) and remove
all protective packaging. Immediately verify that the electrical
rating nameplate located on the cover matches electrical power
supply available. Retain the shipping carton(s) until the air
curtain(s) are installed and properly operating.
ACCESSORIES: If the air curtain(s) were ordered with optional
electrical accessories, the accessories will be found in the carton
containing the air curtain or in a separate carton(s) accompanying the air curtain(s). Check all of the cartons/skids for accessories before discarding.
II. MOUNTING INSTRUCTIONS
(General)
INDOOR MOUNTING ONLY - Environmental/Insect/Dust Control
The Architectural Low Prole 8 Air curtain is designed to be an eective barrier against cold drafts in the winter and hot air in the summer.
To achieve optimum protection, the air curtain should be mounted on
the inside of the building, ush to the wall and as close to the top of
the door opening as possible. To ensure peak performance, keep the
air stream free of obstructions.
The air curtain will not perform properly if negative air pressure
exists in the building. Under these conditions, a means for makeup
air to the building must be provided so that the air pressure on
both sides of the opening is in balance.
Before mounting the air curtain, check the supporting structure to verify that it has sucient load-carrying capacity to support the weight of
the air curtain(s). The mounting hardware (supplied by others) should
be capable of supporting a minimum of three (3) times the weight of
the air curtain.
See Table 1.
If the air stream strikes any obstruction (the top edge
of the doorway, a door opening device, etc.), the
eectiveness of the air curtain will be greatly reduced.
See Figure 1.
B. For optimum performance, the bottom of the air curtain
(discharge nozzle) should be no more than 1” above
the top of the door opening with the air curtain(s)
mounted ush to the wall. If the air curtain must be
mounted higher, it must be spaced out from the
wall ³/₈” for every inch the air curtain is above the door
opening. See Figure 3. For optimum protection, any void
between the air curtain and the wall should be sealed
along the full length of the air curtain.
C. Electric heated air curtain(s) shall:
1. Have a minimum clearance of at least 1”
between the sides and top of the air curtain and
any combustible material.
2. Have a minimum clearance of at least 6’
between the bottom of the air curtain and the oor.
3. Be installed Indoors Only.
D. Proceed to either Section III - WALL MOUNTING
or Section IV - SUSPENDED MOUNTING
III. WALL MOUNTING
A. The Architectural Low Prole 8 Air curtain is equipped with
two ¼” threaded inserts on the back of each air curtain (two
per module on air curtains 84” and over). Insert and
tighten the shoulder bolts (provided in bag taped to the
wall plate) into these threaded inserts. A minimum of two
shoulder bolts are required; on air curtains comprised of
modules, use the outer threaded inserts and a minimum of
one of the inner threaded inserts.
IMPORTANT: A minimum of 1” is required above the top of the
air curtain for the installation and removal of the cover housing.
A. When determining the mounting location for the
air curtain(s), make sure that nothing interferes with the
curtain of air developed when the discharge vanes
are directed from 0º to 20º toward the door opening.
Net Weight
MODEL
Ambient (lbs)
Net Weight
Electric (lbs)
ALC08-1030 33 39 56
ALC08-1036 38 44 64
ALC08-1042 43 49 72
ALC08-1048 48 54 80
ALC08-1060 57 63 95
ALC08-1072 64 70 107
ALC08-2084 86 98 134
ALC08-2096 96 108 150
ALC08-2120 114 126 178
TABLE 1 - Unit Weight
Net Weight
Steam/Hot
Water (lbs)
FIGURE 1 - Mounting Location
2
B. Determine the exact mounting location of the air curtain.
3
/8" Spacers
(for each inch over 4")
Wall Mounting
Plate
Discharge Nozzle
AIR
AIR
NO Obstructions
in Air Stream
Clearance Height
NOTE: A minimum of 1” is required above
the wall mounting plate to provide clearance
for installation and removal of the air curtain.
C. Remove the wall mounting plate from the unit to install.
The wall mounting plate (included) is designed to t ush
with the top of the Architectural Low Prole 8 Air curtain.
Therefore the location of the wall mounting plate will
determine the nal location of the top of the air curtain.
D. For Standard Flush Wall Mounting, position the center of
the wall mounting plate over the center of the door open
ing with the larger opening of the key hole slots facing up.
The wall mounting plate thickness provides a natural ¾”
space which allows for mounting it up to 4” above the
opening. For optimum performance, the bottom of the
mounting plate should be no more than 2” or less than
1” above the top of the door opening.
See Figure 2.
High Wall Mounting must be used if the wall mounting
plate must be mounted higher than 4” above the
door opening: the mounting plate must be spaced out
from the wall ³/₈ ” for every additional inch (over 4”)
that the air curtain is above the door opening (clearance
height). See Figure 3. For optimum protection, do not
exceed the recommended maximum mounting height of
8’ above the nished oor. Any void between the mount
ing plate and the wall should be sealed along the full
length of the mounting plate.
E. Determine which of the four holes provided in each of
the steel brackets of the wall mounting plate are located
where suitable support is available for the air curtain.
A minimum of one inside hole and one outside hole from
FIGURE 3 - High Wall Mounting
that are comprised of modules, remove the wiring tray
cover that is located closest to the electrical rating
nameplate. Remove the required knockouts and
attach the necessary electrical hardware. Save the wiring
diagram found inside of the wiring tray. See Figure 7.
I. There are two sets of keyhole slots on the wall mounting
plate. In low overhead installations, the air curtain may be
staged in the lower keyholes to provide clearance for
electrical wiring and then moved to the higher key holes
after completion. Raise the air curtain with the discharge
opening facing down toward the oor. While
holding the air curtain level, slide the heads of the
shoulder bolts into the larger hole of the keyhole
slots of the mounting plate. Lower the air curtain
into place, keeping both ends level, allowing it to rest ush
with the mounting plate. See Figure 4.
J. After attaching the air curtain to the mounting plate,
ensure that the air curtain is seated and ush with the
mounting plate on all four sides.
K. Proceed to Section V - Electrical Connections.
FIGURE 2 - Standard Flush Wall Mounting
each bracket must be used for proper support.
Drill out the aluminum backing of the holes chosen
with a ¼” drill bit. If the provided holes on the
mounting plate are not located where suitable support
is available, drill new holes in the space provided on
the steel mounting brackets.
F. Mark the wall in the centers of the ¼” holes drilled on the
mounting plate.
G. Attach the mounting plate to the wall (hardware by others).
H. The top of the air curtain is provided with two knockouts
on each side allowing for a left or right hand power
connection. Remove the wiring tray cover; on air curtains
IV. SUSPENDED MOUNTING
(Ceiling Suspension)
A. When the air curtain is top mounted, the wall mounting
plate is designed to store on the back of the air curtain for
future use. See Figure 5.
B. Four (4) factory installed ¼” threaded inserts are located
on the top of the air curtain for top suspension mounting;
on air curtains comprised of modules use the
outer threaded inserts.
To eliminate the slight deection of longer air curtains, the
inner threaded inserts may also be used. See Figure 6.
C. Determine the exact mounting location of the air curtain.
D. The top of the air curtain is provided with two knock outs on each side allowing for a left or right hand
power connection. Remove the wiring tray cover;
on air curtains that are comprised of modules, remove
the wiring tray cover that is located closest to the
electrical rating nameplate. Remove the required
knockouts and attach the necessary electrical hardware.
Save the wiring diagram found inside of the wiring tray.
See Figure 7.
E. Attach ¼” threaded rods or other suitable hardware to the
top mounted threaded inserts.
3
FIGURE 4 - Installing Air Door on Wall Mounting Plate
F. Proceed to Section V - Electrical Connections.
V. ELECTRICAL CONNECTIONS
All electrical wiring and connections MUST be performed by
qualied personnel in accordance with the National Electrical Code ANSI/NFPA No. 70 (latest edition) or, in Canada, the
Canadian Electrical Code, Part 1-C.S.A. Standard C22.1 and local
codes and regulations.
FIGURE 5 - Wall Mounting Plate Storage
A. Check the rating nameplate on the top of the air curtain for
supply voltage and current requirements. See Figure 7.
A separate line voltage supply with a suitable branch circuit
protection device should be run directly from the main
electrical panel to the air curtain. A disconnect switch for
each branch circuit is a required part of this installation.
B. All eld wiring must be copper with a minimum insulation
of 60° C within approved conduit. If any of the wire
supplied with the air curtain must be replaced, it must be
replaced with copper wiring with a minimum insulation of
90° C.
C. Remove the wiring tray cover; on air curtains that are
comprised of modules, remove the wiring tray cover that is
located closest to the electrical rating nameplate (if it has
not already been done).
D. Electric, steam and hot water heated air curtains are factory
equipped with a air curtain mounted solid state
temperature sensor cable (for the Intelliswitch thermostat)
located in the wiring tray. Depending where the tempera
ture is to be measured, the sensor may be left in the wiring
FIGURE 6 - Suspended Mounting
tray or it may be located outside of the air curtain. If the air
curtain is unheated, or the sensor will be left in the wiring
tray, skip to step E, otherwise continue.
1. Remove the ½” bushing taped to the back of the
wiring tray cover and set aside.
2. Determine mounting location of the temperature
sensor (do not mount at this time).
3. Choose end of the wiring tray that the sensor will exit
the air curtain based on the mounting location from
Step 2.
4. Locate the /” hole on the wiring tray next to
the electrical knockout on the side determined in
Step 3.
5. Drill out the /” hole to ½”.
CAUTION: DO NOT DAMAGE EXISTING WIRES IN
THE WIRING TRAY WHEN DRILLING.
6. Maneuver the tip of the temperature sensor from
the inside of the wiring tray out through ½” hole.
7. Thread the tip through ½” bushing from Step 1 and
snap the bushing into the wiring tray.
8. Mount the temperature sensor. Do not put any clamps
on the rubber coated tip.
E. The top of the air curtain has two knockouts on each side
of the air curtain, allowing for a left hand or right hand
power connection. Remove the required knockout if it has
not already been done and connect the power supply to
the air curtain. Connect all supply and control circuit wires
according to the wiring diagram provided.
NOTE: For Electric heated air curtains provided with the
optional remote thermostat, mount and wire the
thermostat according to instructions and wiring
diagram.
F. Master/Slave connection, if two or more units are to be
linked together for master/Slave operation continue, otherwise skip to step G.
4
Electrical Knockouts
Wiring Tray Cover
Electrical Rating
Nameplate
Wiring Diagram and
Temperature Sensor
Inside
FIGURE 7 - Electrical Connections
NOTE: One Intelliswitch serial cable assembly (part #
505SC***INT485-A) is required for every unit that is to
be used as a master/slave. “***” denotes length of cable
in feet- “008” = 8 feet long.
For Master/Slave operation, a serial cable connection must
be made between the INTELLISWITCH GEN2 control boards
of each unit to be linked.
1. Disconnect power to all the units.
2. Access the wiring tray on top of each unit by removing
the screws that hold the cover in place.
3. Find the (RS485) phone jack couplers in the wiring
trays. There will be two short cables in the wiring
tray of each air curtain, each with a double ended
female phone jack coupler attached to the cable.
4. The serial cable ordered for each unit will be coiled up
in the wiring tray of the unit and connected to one of
the couplers.
Note: There may be one less serial cable than the
number of units ordered. e.g. Two units together will
need only one cable; three units together will need two
cables, etc. Any extra cables can be kept as spares.
5. Use one of the extra electrical knockouts to route serial
cable from one unit to the next. Be sure to protect the
edge of the knockout properly.
6. Plug (RS485) male phone jack on the end of the serial
cable into the empty coupler on the next unit.
7. Continue process for all units that are to be connected
serially.
8. Serial cable connections are capable of two way com
munication. It does not matter which coupler the
cables are connected to.
9. The rst and last air curtains in the group will each
have an empty coupler after all connections are made.
So if there are only two air curtains connected, each
will have an empty cable coupler.
Note: If a longer cable is required than was supplied,
it can be ordered from the factory or made by using
standard at telephone cable, phone jack connectors
and the proper crimping tool.
G. Remote mounted Display Faceplate - if operation of the
Intelliswitch is desired through a remote mounted display
face plate continue, otherwise skip to step H.
NOTE: Maximum mounting distance between the Dis-
play Faceplate and the unit is 20’.
The unit MUST be factory ordered with the remote
mounted faceplate option.
1. When the remote faceplate option is ordered
from the factory the air curtain comes equipped with
the blank faceplate and 12’ ribbon attached. The
Diplay Faceplate is shipped loose ready for eld
installation.
2. Locate the male end of the 14-conductor ribbon cable
in the wiring tray and run to the remote display loca
tion. The cable is minimum CL2 rated and should not
need to be in conduit.
3. Connect the ribbon cable to the 14-pin socket with red
stripe positioned on the top left when facing the front
of the display board.
4. Mount remote faceplate to the wall.
H. Reinstall the wiring tray cover.
I. For Electric, Steam and Hot Water air curtains proceed to
Section VI - Field Connections otherwise proceed to
Section VII - Operation and Controls.
VI. FIELD CONNECTIONS
A. ELECTRICALLY HEATED MODELS
The heater circuit may be controlled by a remote
thermostat or manually through the Intelliswitch located
on the discharge side of the air curtain. Overheating
protection is provided by auto reset thermal
cutouts built into the heater coil assembly
(see the wiring diagram).
B. STEAM OR HOT WATER HEATED MODELS
Piping should be done in accordance with local
codes, regulations and standard practices.
Connect the building system supply and return to
the ¾” MPT nipples on the heating coil. See Figure 8.
FIGURE 8 - Steam/Hot Water Connections
5
VII. OPERATING INSTRUCTIONS
A. GENERAL OPERATION
Air curtain operation may be divided into four areas:
control package, fan activation, fan speed selection,
and heat activation. The air curtain must be properly
installed before it is used.
1. Control packages control the unit’s sequence of operation.
Unit modes/control packages are built into the unit and may
not be changed in the eld.. Refer to your wiring diagram
for specics about activation connections and sequence of
operation.
a. Basic Control Package – The unit is activated by a door
switch. The door switch may be line voltage or low
voltage (24V).
b. Deluxe Control Package – The unit is activated by a door
switch, but has a factory installed time delay allowing
the unit to keep running for a period of time after the
door closes.
c. Comfort Plus Control Package – Available only on heated
units, the unit is activated by the door switch OR by the
thermostat to provide supplemental heating.
2. Unheated units will have the fans activated by a door switch
or sensor. The unit speed can be selected from the
Intelliswitch display.
FIGURE 9 - Airow Adjustment
3. Heated units will have fans activated by a door switch or
sensor, but may also be activated by the thermostat in
Comfort Plus Mode. The unit speed can be selected from the
Intelliswitch display.
4. Heat activation is controlled by either a unit or remote
mounted thermostat, and a unit or remote mounted switch.
B. AIR STREAM ADJUSTMENT
1. With the air curtain operating and the door in its full open
position, check to see that nothing is obstructing the airow
at the discharge nozzle vanes.
2. Find the air stream split location. Hold a handkerchief by
its corners, approximately 12” above the oor. Gently move
the handkerchief back and forth in the doorway. Make sure
the air is being directed to both the inside and the outside.
See Figure 9. The split location is indicated where the
handkerchief is vertical with minimal or no uttering.
3. The split location should be approximately 3” outside the
doorway. If necessary adjust the discharge nozzle vanes by
de-energizing the unit, loosening the nozzle vane locking
screws and adjusting vanes.
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