Berner ASF1036 Installation Manual

READ AND SAVE THESE INSTRUCTIONS

No. II-123 Date June, 2010

Installation & Maintenance Instructions

TABLE OF CONTENTS

I. UNCRATING............................................................................................................................................................ 2

II. MOUNTING INSTRUCTIONS ............................................................................................................................... 2

III. WALL MOUNTING .............................................................................................................................................. 3

IV. SUSPENDED MOUNTING.................................................................................................................................. 3

V. ELECTRICAL CONNECTIONS ............................................................................................................................. 3

VI. MECHANICAL CONNECTIONS ......................................................................................................................... 4

VII. AIRFLOW ADJUSTMENTS ................................................................................................................................ 4

VIII. MAINTENANCE AND CLEANING ................................................................................................................... 5

IX. SERVICE ............................................................................................................................................................... 5

TROUBLESHOOTING ............................................................................................................................................... 7

NSF certication requires maximum mounting height of 7 feet for models ASN/STN 36” & 42”

EPH certication requires maximum mounting height of 7 feet for all ASN/STN models

WARNING: TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK OR INJURY TO PERSONS, OBSERVE THE FOLLOWING:

A. Use this unit only in the manner intended by the manufacturer. If you have any questions, contact the manufacturer. B. 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. C. Installation work and electrical wiring must be done by qualied person(s) in accordance with all applicable codes and standards, including re-rated construction. D. Sucient air is needed for proper combustion and exhausting of gases through the ue (chimney) of fuel burning equipment to prevent back drafting. Follow the heating equipment manufacturer’s guideline and safety standards such as those published by the National Fire Protection Association (NFPA), and the American Society for Heating, Refrigeration and Air Conditioning Engineers (ASHRAE), and local code authorities. E. When cutting or drilling into wall or ceiling, do not damage electrical wiring and other hidden utilities.

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I. UNCRATING

Carefully examine the carton(s) for damage before opening. If the carton is damaged, immediately notify shipping company. If the unit(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. Remove the plastic cover housing by lifting vertically. Remove and discard four (4) nuts and washers holding the motor/blower section to the bottom of the carton. Remove motor/blower section from the carton.

CAUTION: ONLY LIFT THE UNIT BY GRASPING INLET RINGS ON THE BLOWER HOUSING WITHOUT TOUCHING BLOWER WHEELS.

Immediately verify that the electrical rating nameplate located on the cover matches electrical power supply available. Retain the shipping carton(s) until the unit(s) are installed and properly operating. ACCESSORIES: If the unit(s) were ordered with optional electrical accessories (door switch, control panel, etc.), the accessories may be found in the carton containing the unit or in a separate carton(s) accompanying the unit(s). Check all of the cartons/skids for accessories before discarding.

II. MOUNTING INSTRUCTIONS (General)

INDOOR MOUNTING - Environmental/Insect Dust Control OUTDOOR MOUNTING (Unheated Only) - Insect/Dust Control

The Aristocrat/Star Air Door is designed to be an eective barrier against cold drafts in the winter and hot air in the summer. To achieve optimum protection, the unit 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 air stream free of obstructions.

The Air Door 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 unit, check the supporting structure to verify that it has sucient load-carrying capacity to support the weight of the unit(s). The mounting hardware (supplied by others) should be capable of supporting a minimum of three (3) times the weight of the unit. See

Table 1.

Model

ASF/STF 1036 ASR/STR/ASN/STN 1036 ASF/STF 1042 ASR/STR/ASN/STN 1042 ASF/STF 1048 ASR/STR/ASN/STN 1048 ASF/STF 1060-2 ASF/STF 1060-3 ASR/STR/ASN/STN2060 ASR/STR 1060 ASF/STF 1072 ASF/STF 2072 ASR/STR/ASN/STN 2072

TABLE 1 - Unit Weight

Net Weight

Amient

(lbs)

50 52 52 54 54 56 56 60 70 58 70 80 84

Net Weight

Electric

(lbs)

55 57 57 59 59 61 61 65 75 63 75 85 89

FIGURE 1 - Air Stream

NOTE: The Air Door is weatherproof, therefore no special covering is

required for outdoor mounting. IMPORTANT: A minimum of 4” is recommended above the top of the Air Door for the installation and removal of the cover housing. A. When determining the mounting location for the unit(s), make sure

that nothing interferes with the curtain of air developed when the discharge vanes are directed from 0° to 20° toward the door opening. If the air stream strikes any obstruction (the top edge of the doorway, a door opening device, etc.), the eectiveness of the unit will be greatly reduced. See Figure 1.

B. For optimum performance, the bottom of the unit (discharge nozzle)

should be no more than 1” above the top of the door opening with the unit mounted ush to the wall. If the unit must be mounted higher, it must be spaced out from the wall ³/₈” for every inch the unit is above the door opening. For optimum protection, any void between the Air Door and the wall should be sealed along the full length of the unit.

See Figure 2.

FIGURE 2

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C. Electric heated units shall:

1. Have a minimum clearance of at least 4” between the sides and top of the unit and any combustible material.

2. Have a minimum clearance of at least 6’ between the bottom of the unit and the oor.

3. Be installed indoors only.

D. Proceed to either Section III - WALL MOUNTING, or Section IV

SUSPENDED MOUNTING

III. WALL MOUNTING

To prevent damage to the Air Door during shipping, the unit is shipped with each blower attached to the back plate by two phillips head screws. These screws should be removed before installation.

See Figure 3.

FIGURE 3 - Mounting Screws

A. The Aristocrat/Star Series Air Door is equipped with ¼” keyhole

mounting slots on the back of each unit for wall mounting. It is recommended that a minimum of two keyhole slots are used from each

end. B. Determine the exact mounting location of the Air Door unit. NOTE: A minimum of 4” is recommended above the unit to

provide clearance for installation and removal of the unit blower

assembly.

C. Choose four (4) keyhole slots that are located where suitable support

is available for the unit. If the keyhole slots are not located where

suitable support is available, drill new holes in the unit backplate

where space is available. D. Mark the wall in the top center of the keyhole slots or in the center of

the holes drilled. E. Keyhole Mounting: Install the mounting hardware (supplied by others), allowing for

space to hang the unit by not fully tightening. Lift and slip the

blower assembly over the mounting hardware by grasping the inlet

rings on the blower housing, without touching the blower wheels.

Tighten the mounting hardware. See Figure 4. Drilled Mounting Holes: Lift the blower assembly by grasping the inlet rings on the blower

housing, without touching the blower wheels, and install the mount-

ing hardware (supplied by others) through the drilled holes.

FIGURE 4 - Keyhole Mounting

F. Do not install the cover housing at this time. G. Proceed to Section V - ELECTRICAL CONNECTIONS.

IV. SUSPENDED MOUNTING (Ceiling Suspension)

NOTE: TWO (2) TOP MOUNTING BRACKETS

(PART#66LWA000TOP)ARE REQUIRED

PER UNIT FOR SUSPENDED MOUNTING.

To prevent damage to the Air Door during shipping, the unit is shipped with each blower attached to the back plate by two phillips head screws. These screws should be removed before installation. See Figure 3. A. The Aristocrat/Star Series Air Door is equipped with keyhole mount-

ing slots on the back of the unit. The top mounting brackets are designed to attach to these keyhole slots.

B. Attach the top mounting brackets to the unit using the hardware

provided. C. Determine the exact mounting location of the Air Door unit. D. Attach /” threaded rods or other suitable hardware to the coupling

nuts, located on the mounting bracket(s). E. Do not install the cover housing at this time. F. Proceed to Section V - ELECTRICAL CONNECTIONS.

V. ELECTRICAL CONNECTIONS

All electrical wiring and connections MUST be performed by qualied personnel in accordance with the latest edition of the National Electrical Code ANSI/NFPA No. 70 or, in Canada, the Canadian Electrical Code, Part 1-C.S.A. Standard C22.1 and local codes and regulations. A. Check the rating nameplate on the unit for supply voltage and

current requirements. A separate line voltage supply with a suitable

branch circuit protection device should be run directly from the

main electrical panel to the unit. A disconnect switch for each branch

circuit is a required part of this installation. See Tables 2 & 3. 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 unit

must be replaced, it must be replaced with copper wiring with a

minimum insulation of 90° C. C. Remove the junction box cover located on the right-hand side of the

unit. See Figure 5. D. Connect all supply and control circuit wires according to the wiring

diagram. To connect wiring from the left-hand side, an optional

knockout is provided.

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FIGURE 5 - Junction Box

NOTE: Electric heated units may be provided with a line voltage

thermostat. Mount and wire thermostat according to instructions and the wiring diagram.

E. Install the cover housing and attach it temporarily at each end of the

unit with two of the cover screws provided. Final assembly should be done after airow adjustments. See Figure 6.

F. Switch on the power at the service disconnect. Turn on the unit and

check the sequence of operation against the wiring diagram.

G. Proceed to Section VI - MECHANICAL CONNECTIONS for electric

heated units, otherwise proceed to

Section VII - AIRFLOW ADJUSTMENTS

VI. MECHANICAL CONNECTIONS

A. ELECTRICALLY HEATED MODELS The heater circuit may be controlled by a remote thermostat, or

manually through a remote mounted three position - fan only/o/ fan with heat switch. Overheating protection is provided by auto reset thermal cutouts built into the blower assembly (see wiring diagram). Proceed to Section VII - AIRFLOW ADJUSTMENTS.

MOTOR VOLTAGES/AMP DRAW S

Horsepower Speed Volts Phase Hertz** Amps per Motor

** Operation at 50 HZ will generate approximately a 17% reduction in performance.

TABLE 2 - Motor Amp Ratings

FIGURE 6 - Removing Cover

3/4

1

120

1

50/60

7.5

3/4

1

208/240

1

50/60

3.8

3/4

1

480

1

50/60

1.8

1/2

3

120

1

50/60

7.2

1/2

3

208/240

1

50/60

4.0

VII. AIRFLOW ADJUSTMENTS

A. With the Air Door operating and the door in its full open position,

check to see that nothing is obstructing the air ow at the discharge nozzle vanes.

B. 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. The split location is indicated where

the handkerchief is vertical with minimal or no uttering. See Figure 7. C. Adjust the discharge nozzle vanes so the split location is ap-

proximately 3” outside the doorway. This is accomplished by rst

de-energizing the unit. Remove the cover housing, loosen the nozzle

vane locking screws and adjusting vanes. D. Install remaining screws in cover housing.

ELECTRIC HEATER DATA

208V 1Ø

Model KW

Amp Draw

Circuit 1 Circuit 2 AS/ST*1036E AS/ST*1042E AS/ST*1048E AS/ST*1060E-2 AS/ST*1036E AS/ST*1042E AS/ST*1048E AS/ST*1060E-2 ASF/STF1060E-3 ASR/STR2060E AS/ST*1072E ASR/STR2072E ASR/STR2072E

*Applies to both ASF/STF front door models and ASR/STR rear door models.

TABLE 3

7.5

7.5 10 10 10 10 15 15 15 15

20.0

36.1

16.0

24.0

48.1

-

32.0

48.1

240V 1Ø

Amp Draw

Circuit 1 Circuit 2

30.8

41.7

20.8

41.7

4

240V 3Ø

Amp Draw

Circuit 1 Circuit 2

-

20.8

27.8

41.6

27.8

-

27.8

240V 3Ø

Amp Draw

Circuit 1

17.8

24.1

36.1

48.1

480V 3Ø

Amp Draw

Circuit 1

-

12.0

18.0

34.0

FIGURE 7 - Air Flow Adjustment

VIII. MAINTENANCE AND CLEANING

CAUTION: ELECTRIC SHOCK HAZARD Disconnect power whenever servicing unit. More than one disconnect may be required to de-energize unit.

Keep your Air Door operating at peak eciency by cleaning the blower wheels, motor(s) and intake grille. Buildup of dust on the blower wheels can cause vibration, noise and excessive wear on the motor bearings. The frequency of cleaning will depend on the environment where the unit is operating. Dirty, dusty or greasy environments could require a cleaning schedule of once every two months. Otherwise, the unit(s) should be scheduled for cleaning a minimum of once every (6) months. To access the interior of the unit: A. Disconnect and lockout power to the unit. Remove unit cover hous-

ing by removing screws from the top and bottom of unit. Slide cover housing away from blower assembly to remove. If the unit has a lter, it should be removed and cleaned at this time. The lter is located in the cover housing and held in place by wing nuts and clips. See

Figure 8.

B. Vacuum and scrape (if necessary) to remove the buildup of dirt and

debris from the interior of the Air Door. The motor(s) are permanently lubricated and require no additional lubrication. Reinstall the cover housing.

C. Switch the power on after cleaning.

CAUTION: STAND CLEAR OF THE UNIT OR WEAR SAFETY GOGGLES AS LOOSE DEBRIS MAY BE PRESENT AND MAY EXIT THE NOZZLE.

IX. SERVICE

CAUTION: ELECTRIC SHOCK HAZARD Disconnect power whenever servicing unit. More than one disconnect may be required to deenergize unit.

Any service performed on the Aristocrat/Star Series Air Door MUST be done by qualied personnel.

Berner Air Doors require very little servicing. All parts are easily accessible for periodic inspection and maintenance. Units should be cleaned at least twice a year. Your particular application (the amount of dirt and dust in the air) and location of the unit(s) will determine how often your unit(s) will need to be cleaned and serviced. All motors have permanently lubricated, sealed, sleeve bearings and require no maintenance.

A. Fan Wheel Removal - Ambient and Electric Heated

1. Disconnect and lockout power to the unit. Remove unit cover housing by removing screws from the top and bottom of unit. Slide cover housing away from blower assembly to remove.

2. If unit is equipped with inlet rings and/or tri-arm bearings, remove outside ring and/or bearing using a blade screw driver or ¼” nut driver. If unit does not have inlet rings proceed to next step.

3. Loosen (do not remove) /” Allen head set screw from hub of fan wheel. Note: a T-handle Allen wrench may be inserted through hole in fan housing and fan blade with semi-circle notch.

4. Carefully slide fan wheel out of fan housing.

5. Reinstall fan wheel and align set screw with at on motor shaft.

6. Slowly tighten set screw while gently rocking fan wheel back and forth to settle set screw perpendicular to motor shaft at.

7. Reinstall inlet ring and/or bearing if necessary.

8. Reinstall unit cover housing and switch on power.

B. Motor Removal - Ambient and Electric Heated

1. Disconnect and lockout power to the unit. Remove unit cover housing by removing screws from the top and bottom of unit. Slide cover housing away from blower assembly to remove. For electric heated units, mark connections and disconnect four spade wire terminals from electric heater(s).

2. Unplug wiring harness from motor.

3. Loosen (do not remove) /” Allen head set screw from hub of each fan wheel attached to motor. Note: a T-handle Allen wrench may be inserted through hole in fan housing and fan blade with semicircle notch. If unit is equipped with an extended shaft and coupling for a three fan, one motor construction, this fan assembly must be disconnected from motor shaft. Loosen /” set screw on third fan wheel hub. Loosen set screw on motor shaft side of coupling (silver coupling - /” Allen wrench, black coupling - /” Allen wrench). Slide coupling and shaft o motor shaft by gently pushing it through third fan hub.

4. Remove four phillips head screws from each fan housing that has a fan attached to motor.

5. Remove each fan and housing assembly from motor shaft by sliding away from motor. After fan wheel is o motor shaft, remove assembly by rotating it away from the blower assembly.

FIGURE 8 - Filter Replacement

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6. While supporting motor, loosen and remove two clips that hold motor with a straight blade screw driver or /” nut driver.

7. Remove motor.

8. Install motor in reverse order of removal.

C. Fan Wheel and Housing Removal Ambient and Electric Heated

1. Disconnect and lockout power to the unit. Remove unit cover housing by removing screws from the top and bottom of unit. Slide cover housing away from blower assembly to remove. For electric heated units, mark connections and disconnect four spade wire terminals from electric heaters.

2. Loosen (do not remove) /” Allen head set screw from hub of fan wheel. Note: a T-handle Allen wrench may be inserted through hole in fan housing and fan blade with semi-circle notch.

3. Remove four phillips head screws from

fan housing.

4. Remove fan and housing from motor shaft by sliding assembly away from motor. After fan wheel is o of motor shaft, remove assembly by rotating it away from blower assembly.

5. Reinstall in reverse order of removal.

D. Filter Replacement

1. Disconnect and lockout power to the unit. Remove unit cover housing by removing screws from the top and bottom of unit. Slide cover housing away from blower assembly to remove.

2. Filter is located in cover housing. Remove wing nuts and clips that hold lter. See Figure 8.

3. Remove and replace lter. Note: clean aluminum lters with water and a mild detergent, rinse thoroughly.

4. Reinstall in reverse order of removal.

Note: do not force or over tighten wing nuts as they will thread through

the outside of cover housing.

E. Electric Heater Removal - Electric Heated

1. Disconnect and lockout power to the unit. Remove unit cover housing by removing screws from the top and bottom of unit. Slide cover housing away from blower assembly to remove. Mark connections and disconnect four spade wire terminals from electric heater(s).

2. Loosen (do not remove) /” Allen head set screw from hub of fan wheel. Note: a T-handle Allen wrench may be inserted through hole in fan housing and fan blade with semi-circle notch.

3. Remove four phillips head screws from fan housing.

4. Remove fan and housing from motor shaft by sliding assembly away from motor. After fan wheel is o of motor shaft, remove assembly by rotating it away from blower assembly.

5. Remove electric heater element from fan housing by removing three screws with ¼“ nut driver.

6. Reinstall in reverse order of removal.

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TROUBLESHOOTING

SYMPTOMS CAUSE REMEDY

NO AIR • Electrical Power supply line open (no power) • Check power source, check method of control in

ON position

• Fuse blown/circuit breaker tripped • Replace fuse(s)/reset breaker

• Motor overload tripped • Internally protected motor - should reset

• Failed switch • Replace switch

MOTOR RUNNING/FANS ARE NOT ROTATING

• Broken or fan hub • Replace fan

• Shaft rotating inside fan • Tighten set screws/tighten fan on shaft

• Broken/Loose coupling • Replace/Tighten coupling

ELECTRICAL CONTROLS NOT FUNCTIONING WHEN DOOR IS OPEN

• Selector switch is in o position • Turn switch to “ON” position

• Door limit switch not operating • Repair or replace limit switch

MINIMUM • Air directional discharge vanes misadjusted • Adjust vanes to proper position, see instructions

• Inadequate intake clearance • Move air curtain or remove obstruction Provide adequate space for air curtain

• Blower motor operates below speed • Improve voltage

• Fan rubbing against housing • Free fan from housing

• Fan wheels clogged with dirt • Clean and vacuum fan wheels

• Air stream too weak •

AIR IS NOT HITTING

see installation instructions

FLOOR

• Air stream hits obstruction • Remove obstruction or reposition air curtain (move out

• Negative pressure • Relieve negative pressure by providing make-up air

• Shaft rotating inside fan • Tighten set screws/Replace fan

UNEVEN AIR

• One motor not operating • Repair or replace motor/Check electrical connections

• Nozzle not angled out far enough • Adjust nozzle angle to outside

EXCESSIVE AIR

• Air movement too cold • Add auxiliary heat to overcome wind chill

MOVEMENT AT

• Pushing air outside building • Adjust discharge angle back into building

DOORWAY

SEE AIR IS NOT HITTING FLOOR SYMPTOMS

automatically after cool-down, if not replace motor.

Adjust nozzle to proper position, adjust motor speed;

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/8” for every 1” up from the door)

ELECTRICALLY HEATED MODELS

NO HEAT • Switch turned to “OFF” position • Turn switch on

• Thermostat not set properly • Change thermostat setting

• Coils burned out due to lack of air • Correct airow problem; replace coils

• Automatic reset thermal cutout failed in open position • Replace automatic thermal cutout

• Manual reset thermal cutout tripped • Reset manual thermal cutout

• Defective switch • Replace switch

NOT ENOUGH • Thermostat in wrong location - thermostat too • Move thermostat away from air stream HEAT close to discharge

• Improper voltage • Supply proper voltage

• Thermostat not set properly • Change temperature setting

TOO MUCH • Thermostat in wrong location • Move thermostat closer to air stream HEAT • Thermostat not set properly • Change temperature setting

• Insucient air over coil • Remove restriction on intake

• Improper voltage • Supply proper voltage

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WARRANTY

Berner International warrants all new equipment to be free of defects in workmanship and material for a period of ve years (5 years) on unheated models and two years (2 years) on heated models from the original date of shipment, provided the equipment has been properly cared for, installed and operated in accordance with the limits specied on the nameplate and The Company’s instructions.

The Company will correct by repair or replacement, at its option and expense, any proven defects in said apparatus, subject to the above conditions, provided that immediate written notice of such defects is given to The Company. The warranty does not include any labor incurred for the removal or installation of defective part(s). The Company reserves the right to inspect, or have inspected by a qualied representative, any apparatus at the place of installation before authorizing repair or replacement. Repair or replacement will be made F.O.B. factory with any applicable transportation charges to be borne by the customer. Merchandise not of The Company’s manufacture supplied in piece, or in component assemblies, is not covered by the above warranty, but The Company will give the customer the benet of any adjustment as made with the Manufacturer.

This warranty is void if the apparatus has been tampered with in any way or shows evidence of misuse.

The Company will not assume any expense or liability for repairs made outside its factory without proper written consent from its service manager, nor for any transportation charges on apparatus returned to the factory without written authorization by The Company.

Nothing in the above warranty provisions, however, shall impose any liability or obligation of any type, nature or description upon Berner International if Berner has not received payment in full for the apparatus in question.

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE OF INCLUDING

THE IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF DAMAGES Notwithstanding anything to the contrary above, customer’s exclusive remedy for any and all losses or damages resulting from the sale of The Company’s equipment under this agreement, including but not limited to, any allegations of breach of warranty, breach of contract, negligence or strict liability, shall be limited, at The Company’s option, to either the return of the purchase price or the replacement of the particular equipment for which a claim is made and proved. In no event shall The Company be liable for any special, consequential, incidental or indirect losses or damages from the sale of The Company’s equipment under this agreement.

SERIAL NUMBER MODEL NUMBER DATE PURCHASED

BERNER INTERNATIONAL CORPORATION

New Castle, Pennsylvania

724-658-3551 • 1-800-245-4455 • www.berner.com • airdoors@berner.com

Berner reserves the right to alter speciﬁcations without prior notice.

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