Berner FCA1036A Installation Manual
No. II-300
Date: August, 2011
READ AND SAVE THESE INSTRUCTIONS
Installation & Maintenance Instructions
For the In-Ceiling Mount Air Curtain with Intelliswitch®
TABLE OF CONTENTS
IN-CEILING MOUNT AIR CURTAIN
I. UNCRATING.................................................................................................................................................................. 2
II. MOUNTING PREPARATION.................... ................................................................................................................... 2
III. MOUNTING ................................................................................................................................................................ 3
IV. ELECTRICAL CONNECTIONS .................................................................................................................................... 3
V. FIELD CONNECTIONS ................................................................................................................................................ 4
VI. AIRFLOW ADJUSTMENTS ........................................................................................................................................ 4
VII. MAINTENANCE AND CLEANING ............................................................................................................................ 4
VIII. SERVICE ..................................................................................................................................................................... 5
TROUBLESHOOTING......................................................................................................................................................19
INTELLISWITCH®
QUICK START PROGRAMMING................................................................................................................................... 8-9
FAQ’s (FREQUENTLY ASHED QUESTIONS)............................................................................................................ 10-11
INTELLISWITCH® DETAILED PROGRAMMING...................................................................................................... 12-18
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 qualied person(s) in accordance with all applicable codes and standards, including
re-rated construction. (See page 4 V. ELECTRICAL CONNECTIONS (NEC Code ANSI/NFPA No. 70)
D. Sucient 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.
www.intelli-how2.com 800-245-4455 www.berner.com
I. UNCRATING
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 door(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
door(s) are installed and properly operating.
ACCESSORIES: If the air door(s) were ordered with optional
electrical accessories, the accessories will be found in the carton
containing the air door or in a separate carton(s) accompanying the air door(s). Check all of the cartons/skids for accessories
before discarding.
II. MOUNTING PREPARATION
INDOOR MOUNTING ONLY - Environmental/Insect/Dust Control
A. The In-Ceiling Mount air curtain is designed to be an ef-
fective 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 with
the ceiling, so that the airstream can pass as close to the
top of the door opening as possible. To ensure peak performance keep the air stream free of obstructions.
B. 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.
C. Before mounting the air door, check the supporting struc-
ture to verify that it has sucient 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.
D. When determining the mounting location for the unit(s),
make sure that nothing interferes with the curtain of air
Model
ICA/FCA1036A 100 104 115
ICA/FCA1042A 107 111 124
ICA/FCA1048A 113 11 7 133
ICA/FCA1060A 133 137 160
ICA/FCA2060A 170 178 197
ICA/FCA2072A 177 185 205
ICA/FCA2084A 202 210 237
ICA/FCA2096A 215 223 256
ICA/FCA3096A 252 264 293
ICA/FCA2108A 222 230 267
ICA/FCA3108A 259 271 304
ICA/FCA3120A 269 281 318
ICA/FCA3132A 291 303 346
ICA/FCA3144A 304 316 364
ICA/FCA4144A 341 357 401
Total Net
Weight Ambient
Total Net
Weight - Electric
Heat
Total Net
Weight - Steam/
Hot Water Heat
Table 1
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 eectiveness of the unit will be greatly
reduced. See Figure 1.
E. For optimum performance, the bottom of the discharge
nozzle should be located in such a manner that it is spaced
Figure 1
out from the wall 3/8” for every inch the unit is above the
door opening.
F. Electric heated unit(s) shall:
Have a minimum clearance of at least 6’ between the 1.
bottom of the unit and the oor.
Be installed Indoors Only.2.
The unit is shipped without the front and back trim 3.
installed to protect it from shipping damage. This trim
need not be installed until after the unit is hung. See
Figure 2.
Figure 2
2
III. MOUNTING
A. The ICA/FCA series air door enclosure is equipped with four
5/16”-18 threaded inserts on the top of the unit for suspended mounting. See Figure 3.
Figure 3
For lighter lifting the blower assembly may be removed
so that the enclosure can be easily installed. See
Section VIII: SERVICE for instruction on removing the
blower assembly.
B. The electrical junction box is located on the outside of the
enclosure on the left side of the unit.
C. Determine the exact mounting location of the air door unit.
D. Create structural attachment points to suspend the unit
above the ceiling so that the unit is centered and parallel
with the door opening.
E. Suspend air door cabinet by attaching threaded rods to
the unit and support structures. Adjust unit position so
the bottom of the cabinet is ush with the underside of the
ceiling.
F. Install the front and back trim using the provided fasteners.
See Figure 3.
G. Finish o ceiling edge as required.
NOTE: Finishing materials must not overlap the bottom of
the cabinet to allow the intake screen to open freely.
H. If the blower assembly was removed, re-install it along with
nozzle surround and bottom access cover.
IV. ELECTRICAL CONNECTIONS
All electrical wiring and connections MUST be performed by
qualied 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 Table 2 & 3 for component electri-
cal loads. See the voltage label on the unit for circuiting
and total electrical load.
Motor Voltages/Amp Draws
Volts 120 208 240 208 240 480 600 220 380
Phase 1 1 1 3 3 3 3 1 1
Hertz 60 60 60 60 60 60 60 50 50
Amps per Motor 6.5 3.5 3.5 3.5 3.5 1.4 1
3.5 3.5
Table 2
Heater Amp Draws for Selected kW
Heater kW
6 kW 28.9 25.1 16.7 14.5 7.2 6.0
8 kW 38.5 33.5 22.2 19.3 9.6 8.0
10 kW 48.1 41.9 27.8 24.1 12.0 10.0
12 kW 57.7 50.3 33.4 28.9 14.4 12.0
14 kW 67.3 58.7 38.9 33.7 16.8 14.0
16 kW 77.0 67.0 44.5 38.6 19.2 16.0
18 kW N/A N/A 50.0 43.4 21.6 18.0
20 kW N/A N/A 55.6 48.2 24.0 20.0
24 kW N/A N/A 66.7 57.8 28.8 24.0
28 kW N/A N/A 77.8 67.5 33.6 28.0
30 kW N/A N/A 83.4 72.3 36.0 30.0
32 kW N/A N/A 88.9 77.1 38.4 32.0
40 kW N/A N/A 111.2 96.4 48.0 40.0
42 kW N/A N/A 116.8 101.2 50.4 42.0
56 kW N/A N/A 155.7 135.0 67.2 56.0
Amps per kW 4.81 4.19 2.78 2.41 1.20 1.00
208/1 240/1 208/3 240/3 480/3 600/3
Heater kW Amp Draws
Table 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. Electric, steam and hot water heated air doors are factory
equipped with an air curtain mounted solid state temperature sensor cable (for Intelliswitch® thermostat) located
on the outside of the left endplate. Depending on where
the temperature is to be measured, the sensor may be left
on the endplate or positioned elsewhere. Do not put any
clamps on the rubber coated tip.
D. Remove the junction box cover.
E. Connect all supply and control circuit wires according to
the wiring diagram provided.
NOTE: For Electric heated air doors provided with the op
tional remote thermostat, mount and wire the thermostat
according to instructions and wiring diagram.
F. Master/Slave connection, if two or more air doors are to
be linked together for Master/Slave operation, continue,
otherwise, skip to Step G.
NOTE: The air door must have been ordered from the
factory with this option.
NOTE: One Intelliswitch® serial cable assembly (part #
505SC***INT485-A) is required for every air door that is to
be used as a Master/Slave. “***” denotes length of cable in
feet “008”= 8 ft. long.
3
For Master/Slave operation, a serial cable connection must be
made between the Intelliswitch® control boards of each air door
to be linked.
1. Disconnect power to all the air doors
2. Find the (RS485) phone jack couplers protruding through
the hole in the endplate next to the j-box.
3. The serial cable ordered for each air door will be coiled up
and attached to the left endplate.
NOTE: There will be one less serial cable than the number of
air doors ordered. E.g. Two air doors together will need only
one cable; three air doors together will need two cables,
etc. Any extra cables can be kept as spares.
V. FIELD CONNECTIONS
A. ELECTRICALLY HEATED MODELS
The heater circuit may be controlled by a remote thermo-
stat or manually through the Intelliswitch® located on the
discharge side of the air door. Overheating protection is
provided by auto reset thermal cutouts built into the heater
coil assembly (see the wiring diagram).
B. STEAM AND 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 4.
4. Plug the (RS485) male phone jack on the end of the serial
cable into the empty coupler on the next air door.
5. Continue process for all air doors that are to be connected
serially.
6. Serial cable connections are capable of two way communication. It does not matter to which coupler the cables are
connected.
7. The rst and last air door in the group will each have an
empty coupler after all connections are made. If there are
only two air doors 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 4
wire at telephone cable, phone jack connectors and the
proper crimping tool.
G. Remote Mounted Display Faceplate – If operation of the
Intelliswitch® is to be through a Factory Ordered Remote
Mounted Display Faceplate, continue, otherwise, skip to
step H.
NOTE: Maximum mounting distance between the Display
Faceplate and the air door is 20’.
1. When the remote faceplate option is ordered from the
factory, the air door comes equipped with the blank
faceplate already installed and the 20’ ribbon cable attached. The Display Faceplate is shipped loose, ready
for eld installation.
2. Locate the male end of the conductor ribbon cable
and run it to the remote display location. The cable
is minimum CL2 rated and should not need to be in
conduit.
3. Connect the female end of the ribbon cable to the
14-pin socket on the back of the display board with
the cable approaching from the top and the red ribbon
indicator to the right (when facing the front of the
display board).
4. Mount Display Faceplate to the wall.
H. For Electric, Steam and Hot Water air doors proceed to
Section V - Field Connections otherwise proceed to
Section VI - Airow Adjustments
VI. 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.
Figure 4
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 5.
C. Adjust the discharge nozzle vanes so the split location is
approximately 3” outside the doorway. Loosen the nozzle
vane locking screws and adjusting the vanes.
VII. MAINTENANCE AND CLEANING
CAUTION: ELECTRIC SHOCK HAZARD Disconnect power
when ever servicing unit. More than one disconnect may be
required to de-energize unit.
Keep your air door operating at peak eciency 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:
4
Figure 5
sealed, sleeve bearings and require no maintenance.
A. To remove the blower module and clean or replace the fans
and motor:
1. Disconnect and lockout power to the unit.
2. Remove the bottom access cover by removing (4) Phillips head machine screws located at the cover’s corners.
See Figure 6.
3. If desired, the nozzle surround may be removed to
provide more working room. To remove the nozzle surround, remove the (4) Phillips head machine screws from
the corners. The Intelliswitch® ribbon cable must also be
disconnected from the back of the display circuit board
A. Disconnect and lockout power to the unit. If necessary
remove the blower assembly. See Section VIII: Service for
instructions on how to remove blower module.
B. Remove the bottom access cover by removing (4) Phillips
head machine screws located at the cover’s corners. See
Figure 6.
C. 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.
D. Pull the lter out from underneath the struts of the bottom
access cover. It is easiest to work from the middle, pulling
one side out and then the other. Spray the lter with warm,
soapy water, rinse, and pad dry.
E. Replace Filter.
F. Reinstall the bottom access cover.
G. 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.
VIII. SERVICE
CAUTION: ELECTRIC SHOCK HAZARD Disconnect power
when ever servicing unit. More than one disconnect may be
required to de-energize unit.
Figure 6
before the nozzle surround can be set aside.
4. Disconnect motor power wires/harness from motor.
5. If the unit has electric heat, the heaters need to be
disconnected from supply wiring. Each fan housing will
have a heating element on both of its sides, spanning
the inlet venturi. Each heating element will have (2) ¼”
quick disconnects for power supply wiring. In addition,
the heating elements located on the outside of the module will have (2) ¼” quick disconnects for the auto reset
thermal cutouts. Label and separate all of those connections. See Figure 7.
6. Using a 5/16” hex driver, loosen and remove the (4) self
drilling screws that hold the blower plate to the frame of
the unit. Remove the two screws at the top of the product last, as after they are removed, the module will be
Any service performed on the ICA/FCA air door MUST be done
by qualied 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,
Figure 7
5
free to drop out of the cabinet. See Figure 8 for location
of all screws.
7. Wearing protective gloves, hold the module by the motor, and rotate the module top forward and drop it down
through the bottom of the unit. See Figure 9.
8. To remove the fans and/or motor, loosen the set screws
in the fan wheel hubs by using a 5/32” Allen wrench
that is at least 6” long. The set screw can be accessed up
through the fan’s discharge.
9. Next, remove the two blower housings by removing the
(8) screws that attach the fan housings to the blower
plate. When the fan housings are free, slide them and
their fan wheels o to each side.
10. Remove the motor clips from the motor mounts, disconnect the motor ground wire if necessary, and lift the
motor up and out of its cradle.
11. Reinstall in reverse order of removal.
B. To Replace the Electric Heater:
1. Disconnect and lockout power to the unit.
2. Remove the bottom access cover.
3. The blower module does NOT need to be removed from
the unit to replace electric heaters, unless you have one
of the following models: ICA1036, ICA2060, or ICA3096.
If you have one of these models, you will need to remove
the blower module to replace the outer heaters. If you
need to remove the blower module, see Section VIII
Service, A.
4. Label and detach the heater connections for supply
power and for the auto reset thermal cutout.
5. Remove the (2) self drilling, heater retention screws holding the electric heater frame to the fan housing. See
Figure 10.
6. Carefully maneuver the heater out from the fan and
Figure 8
Figure 9
6
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