Mars Air EP2-48 Installation Manual

Document No: IND2-IOM

Date: 1015

STANDARD 2 (STD2), HIGH VELOCITY 2 (HV2), EXTRA POWER 2 (EP2)

AND ETL SANITATION CERTIFIED INDUSTRIAL SERIES

Installation, Operation and Maintenance Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or
maintain the product described. Protect yourself and others by observing all safety information. Failure to comply
with these instructions could result in personal injury and/or property damage. Retain these instructions for future
reference.

OVERVIEW

Mars Air Curtains are
designed to cover door
openings, providing both
temperature
control/environmental
separation and flying insect
control, when the building’s
doors are opened. Typical
installation heights are:
Standard 2 Series
(Environmental up to 10’,
Flying Insect Control up to 8’),
High Velocity 2 Series
(Environmental up to 12’,
Flying Insect Control up to 10’), and Extra Power 2
Series (Environmental up to 16’, Flying Insect Control
up to 14’). All ETL Sanitation Certified Series should be
mounted at the Flying Insect Control heights referenced
above. The units are typically wall mounted horizontally
above the door opening. They can also be suspended
from the ceiling or vertically mounted along side the
opening. The units are ETL Listed for either an inside
or outside mount. Heated units must be mounted on
the inside or the protected side of the opening. The
motors used in the Standard 2, High Velocity 2 and
Extra Power 2 Series are 1/2HP, 1HP and 3HP
respectively. The ETL Sanitation Series utilizes 1/2HP
and 1HP motors.

The Standard 2, High Velocity 2 and Extra Power 2
Series come standard with an air intake grille. They can
also be configured with an aluminum mesh air intake
filter instead of the air intake grille or in conjunction with
it.

GENERAL SAFETY INFORMATION
Use this product only in the manner intended by the

coming in contact with moving parts, as well as other
potential hazards.

WARNING

To reduce the risk of fire, electric shock or injury to
persons, observe the following.
A. Always disconnect, lock and tag power source before

installing or servicing product.

B. Installation work or electrical wiring must be done by

qualified person(s) in accordance with all applicable
codes and standards, including fire-rated construction.

C. The combustion airflow needed for safe operation of

fuel burning equipment in the area may be affected by
the product’s operation. Follow the heating equipment
manufacturer’s guideline and safety standards, such
as those published by the National Fire Protection
Agency (NFPA), the American Society of Heating,
Refrigeration and Air Conditioning Engineers
(ASHRAE) and local code authorities.

D. When cutting or drilling into a wall or ceiling, be careful

not to damage electrical wiring and other hidden
utilities.

manufacturer. If you
have any questions,
contact the
manufacturer. Only
qualified personnel
should install this
product. Installing
personnel should have
a clear understanding
of these instructions
and should be aware
of general safety
precautions. Improper
installation can result
in electric shock,
possible injury due to

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WARNING

Precaution should be taken in explosive atmospheres.

WARNING

When servicing the product, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.

RECEIVING AND INSPECTION

Upon receiving the product, check to make sure all
items are accounted for by referencing the Bill of Lading
to ensure all items were received. Inspect each carton
for shipping damage before accepting delivery. Notify
the freight carrier if any damage is noticed. The carrier
will make notification on the delivery receipt
acknowledging any damage to the product. All damage
should be noted on all copies of the Bill of Lading which
is countersigned by the delivering carrier. A Carrier
Inspection Report should be filled out by the carrier
upon arrival and a report given to the Traffic
Department. If damaged upon arrival, file a claim
immediately with the carrier. Any physical damage to
the unit after acceptance is not the responsibility of
Mars Air Systems.

UNPACKING

Verify that all parts, components and accessories, and
the correct quantities of each have been received. If
any items are missing, report shortages to Mars Air
Systems directly to arrange for obtaining the missing
items. Again, verify quantities received against those
on the Bill of Lading only, as multiple shipments may be
involved.

INSTALLATION

Typical Mounting – Wall or Ceiling Mounted
Horizontally Above the Door Opening

1. Remove the air intake grille(s) and/or filter(s) from the
product and set aside. Only products 48” or less,
except HV2 and EP2 models, are shipped with the
motor fan assembly (MFA) mounted inside.

2. Measure the housing and center it over the opening.
The air curtain shall be equal to or greater than the
width of the opening.

3. Total of two (2) key-hole slots and six (6) pre-punched
mounting holes are provided for your convenience.
The 7/16” pre-punched holes (4) provided, (2) on each
end for top/celling mounts. The 1/2” key-hole slot and
7/16” pre-punched hole (2) provided, (2) on each end
for wall mounts. These holes must be utilized to secure
the product to the wall or ceiling. If necessary, holes
may be drilled inside the product
spacing. All hardware is field provided by others.

to align with the stud

4. Mount the product such that the discharge is 1” above
the opening and all obstacles. (FIG. 1)
Note: If the product is installed higher than the
recommended 1” above the opening, then it must be
moved 3/8” away from the wall for every 1” that it is
moved up. Any void between the wall and the product
must be sealed, by others, to optimize performance.

5. Use four (4) threaded rods for overhead installation or
four (4) threaded bolts for wall installation. All
hardware is field provided by others. (FIG. 1)

6. If applicable, optional Adjustable Mounting Brackets,
Side Extension Plates and Extended Wall Mounted
Brackets are also available for installations over a
Vertical Lift or Drum Roll-up type door. (Reference
Accessory Installation Supplement)

7. If applicable, for tandem installation or products
mounted side by side, allow no more than 6” between
the two products. For overhead installation using
threaded rods, the products may require a beam, by
others, to span the full distance of the mounting length.
(Reference Accessory Installation Supplement)

8. All wires must be connected internal of the unit and
some knockouts are provided. However, it may be
necessary to create your own knockout, as required.

9. The unit must be wired per NEC and local codes.

FIG. 1

Motor Fan Assembly Installation and Electrical Field
Wiring

1. Once the housing is installed over the opening, the
Motor Fan Assembly (MFA) must be re-placed and
securely fastened. For products with the MFA shipped
loose, wing nuts or hex nuts are provided inside the
unit (FIG. 2). For heated MFA installation, reference
Heated Products Supplement Sheet.

2. The unit and any optional accessories must be wired
with the proper voltage to the junction box per the
wiring diagram. (FIG. 3, unheated products only)

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3. All 3 phase motors are bi-directional, which means
they can rotate in either direction. Follow directional
arrows on the blower wheel housings for proper
rotation. If the motor is rotating incorrectly, switch two
of the 3 phase power or motor leads and the motor will
rotate the opposite direction. Make sure all motors are
turning in the same and proper direction. (FIG. 2)

4. Replace the air intake grille(s) or filter(s) once the
product has been properly tested.

FIG. 2

START-UP
This product has been assembled and tested at the

factory prior to shipping. The following procedures
should be performed to assure its performance. Before
continuing with the start-up, it is important to recognize
the safety controls furnished with the unit.

WARNING

The following items must all be completed by a qualified
installer and checked off when completed

A. Re-check that the product has been installed properly

and is level and secure.

B. Check all terminal screws are tight and field wiring is

connected in accordance to National Electrical Code
and wired per the enclosed wiring diagram. For
electric heated models, ensure that the coils are
secured and not touching each other on any metal
surface.

C. Verify proper voltage prior to powering the product.

(See product label for reference).

D. Check all field wired components “if supplied” are

wired correctly.

E. Check that the inlet air supply and the discharge air

supply are free of obstructions.

F. Check that all air filter(s) and/or air intake grille(s) are

in place and installed properly, as originally shipped.

G. Verify voltage to the product once more and turn

power on.

H. Regardless of whether the product is mounted on the

inside or outside of the door opening, set the air
directional vanes in the discharge nozzle slightly
outward to approximately 10-15° towards the outside,
or the wind load. (FIG. 4)

FIG. 3

NOTE

For accessory installation, reference Accessory
Installation Supplement.

For heated products, reference Heated Products

Supplement.

FIG. 4

I. For products with control panels, turn the HOA (Hand-

On-Auto) selector switch to “On” position and open
the door to energize the product. For products without

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a control panel or an On/Off switch, open the door
to energize the product.

J. If heated products are installed, reference Heated

Products Supplement.

K. For three phase units, verify direction of rotation of

blower wheels (note direction arrows on the blower
wheel housing). Correct if needed by changing
polarity of three phase power.

L. VERY IMPORTANT Using a clamp meter, measure

the amperage to each motor and ensure that they
do not exceed the amperage listed on the product
label.

M. If applicable, adjust the air intake grille(s) such that

the output air stream reaches the floor. For
temperature control and environmental separation
applications, the air stream should reach the floor
with sufficient strength to create an air seal around
the door opening without creating turbulent mixing
of the inside and outside air. For flying insect
control applications, the air stream should reach the
floor with maximum strength. If after proper
installation and adjustment, the product appears to
be producing too little or too much air for the
application, contact the manufacturer.

WARNING

Prevent hazard of electrical shock. More than one
disconnect switch may be required to de-energize this
product.

MAINTENANCE

To reduce the risk of fire, electrical shock or injury to
persons, observe the following:
A. Maintenance is to be performed only by qualified

personnel who are familiar with local codes and
regulations and are experienced with this type of
product.

B. Before servicing or cleaning the product switch power

off at service panel and lock service panel to prevent
power from being switched “ON” accidentally.

Routine maintenance is required to keep this product
operating at its peak performance and efficiency. Over
time, the housing, air intake grille, air intake filter,
blower wheels and motor(s) will accumulate a build up
of dust, debris and other residue. It is imperative to
keep these components clean. Failure to do so will not
only lower operational efficiency and performance, but
also reduce the useful life of the product. The time
between cleanings depends on the application, location
and daily hours of use. On average, under normal use
conditions, the product should require a thorough
cleaning once every six (6) months.

WARNING

To clean the product, perform the following:

1. Verify the product has been disconnected from the
power source.

2. Use a damp cloth and either a warm mild soapy water
solution or bio-degradable degreaser, to wipe down
the exterior components of the housing.

3. To access the interior of the product, remove the air
intake grille and/or air intake filter. This is
accomplished by removing the eight (8) self-tapping
screws on the face of each air intake grille/filter.

4. Thoroughly clean the air intake grille/filter.

5. Remove the motor fan assembly (MFA) from inside the
air curtain housing. This is accomplished by loosening
the watertight fitting and pulling the cord out (3 phase
power) or by the quick disconnect plug on the motor (1
phase power). Then remove the two (2) wing nuts on
the out board sides of the MFA pan. Care should be
taken to avoid the MFA from tipping over.

6. Remove the MFA from the unit and thoroughly wipe
down the motor, blower wheels and blower wheel
housings. Be careful not to submerge the motor in
water or spray it with a water hose.

7. The motor(s) require no additional lubrication. They
are permanently lubricated and feature double sealed
ball bearings.

8. To re-install the product, reverse the procedures
above.

9. Reconnect the power source to the product

10. If you have any questions regarding the maintenance
of the product, contact the manufacturer.

SPECIAL APPLICATIONS

Outdoor Installation

For outdoor unit special consideration may be required
for enclosure, motor, wheel and other components to
minimize damage caused by exposure to the outdoor
elements. Contact factory for special construction and
costing.

Freezer and Cooler Installation

Air curtain must be mounted on the warm side for
optimal performance. Variable Frequency Drive (VFD) is
strongly recommended to control the air curtain air flow
velocity at the floor level.

High humid areas may require de-humidifier or
additional defrost cycle to minimize condensation and
freezing for freezer applications. We recommend the air
curtain unit to not replace doors but work in conjunction
with door opening sequence cycle.
Contact factory for details.

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CAUTION

The appliance is not to be used by persons (including
children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction.
Children are not to play with the appliance.

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

NO AIR BLOWING OUT
OF DISCHARGE NOZZLE

- Circuit breaker is tripped - Reset circuit breaker

- Blown fuses on power supply - Replace fuses

- Motor overload is open or tripped

- Failed switch - Replace or repair limit switch
MOTOR IS RUNNING BUT
FANS ARE NOT
SPINNING

- Loose set screws on wheel hubs - Tighten set screws on motor shaft flats

- Fan spinning inside fan housing - Tighten fan on shaft or replace fan

- Broken fan hub - Replace fan wheels
ELECTRICAL CONTROLS
NOT WORKING WHEN
DOOR IS OPEN

- Door limit switch is not operating - Repair or replace door limit switch
UNIT WILL NOT TURN

OFF
LOW AIR FLOW - Discharge air vanes out of adjustment

- Obstruction on intake or discharge - Remove obstruction or move air curtain

- Power leads out of polarity

- Blower motor rotating below normal speed

- Fan rubbing against housing - Free fan from housing

- Blower wheels clogged with dirt - Clean and remove dirt from blower wheels
EXCESSIVE AIR
VELOCITY AT DOOR
OPENING

- Air temperature too cold - Add auxiliary heat to overcome wind chill

- Air stream pushing air outside of the building - Adjust discharge angle back into building

AIR NOT HITTING THE
FLOOR

- Obstruction in the direction of air flow

- Negative building pressure
UNEVEN AIR - Shaft rotating inside fan - Replace fan or tighten fan on shaft

- One motor not functioning - Replace or repair motor
EXCESSIVE NOISE AND
OR VIBRATION

- Loose set screws on wheel hubs - Tighten set screws on motor shaft flats

- Fan spinning inside fan housing - Tighten fan on shaft or replace fan

- Broken fan hub - Replace fan wheels

- Bearing end caps worn - Replace Bearing end caps

- Damaged blower wheel - Replace Blower Wheel

- Bearing end caps worn - Replace Bearing end caps

- Balancing clips missing - Replace Blower Wheel

- No power being supplied to the unit from
the electrical power source

- Motor contactor / relay defective
(if applicable)

- Loose or broken coupling (belt drive) - Replace or tighten coupling

- Switch is in off position - Turn unit's switch to the on position

- Door limit switch is permanently closed or
energized

- Nozzle out of adjustment and not angled far
out enough (BD only)

- Low air velocity

- Loose or broken coupling (belt drive) - Replace or tighten coupling

DISCLAIMER

Mars reserves the right to change specifications and
product design without notice. Such revisions do not
entitle the buyer to corresponding changes,
improvements, additions or replacements for
previously purchased equipment.

- Confirm power source / check if in on position

- Allow the motor to cool down; motor has auto reset internal
overload; if unit is panel equipped, press reset button on
overload inside panel, or replace motor overload if overload
remains tripped

- Check voltage to coil; check contacts to see if they are pulling in

- Position the door switch in a manner that turns off the unit when
the door closes, and turns on the unit when the door opens.
Only light pressure required.

- Adjust vanes to proper position (Refer to Start­Up Section in this manual)

- Switch power leads to correct polarity
(3 phase models only)

- Apply proper voltage per unit requirement (see unit
label) / Adjust adjustable motor speed knob (if applicable)

- Adjust nozzle angle to outside

- Adjust vanes to proper position or check installation height

(Refer to Start-Up Section in this manual)

- Remove obstruction or move air curtain

(Move out 3/8" for every 1" up from the door)

- Provide a make-up air system to relieve negative building
pressure

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WARRANTY

Mars’ warranty coverage, period, extent and
limitations apply to the product only. It does not
apply to labor. Mars warrants that Mars product 1)
Is free from defects in materials and workmanship
and 2) Conforms to Mars’ published specifications.
The warranty period for Mars product except heated
and custom models, is a five (5) year period
commencing on its date of shipment. The date on
customer’s invoice is the date of shipment, unless
Mars or your reseller informs you and Mars
otherwise. For heated products, the warranty
period is an eighteen (18) month period and for
custom products and accessories, the warranty
period is twelve (12) months period commencing
the date of shipment. Mars will provide free
replacement of any part that fails as a result of a
defect in material or manufacturer’s workmanship.
Changes in operational specification parameters
that are different from those provided on the original
purchase order are not covered. Mars product is
inspected and tested before packaging and is
shipped in working condition. The warranty for
Mars product only covers free-of-charge
replacement of failed parts. The warranty does not
cover labor and transportation expenses that may
be required to provide and to install replacement
parts. Because in many instances, it is impossible
to determine the cause of failure, customer may be
responsible for transportation charges associated
with replacement of failed part. Mars does not
warrant uninterrupted or error-free operation of
Mars product. Under no circumstance is Mars liable
for any of the following: 1) Third-party claims
against you for damages; or 2) Special, incidental,
or indirect damages or for any economic
consequential damages (including lost profits and
savings), even if Mars, its suppliers, or its reseller is
informed of their possibility. The warranty does not
cover repair or exchange of Mars product resulting
from misuse, accident, modification, unsuitable
physical or operating environment, improper
maintenance and installation by customer, or failure
caused by a product for which Mars is not
responsible. The warranty does not cover damages
caused by mishandling during transportation. The
warranty is voided by removal or alteration of Mars
product or parts identification labels, by improper
installation of product, and resulting non-compliance
to federal, state and local codes and regulations.
Additionally, Mars reserves the right to void the
warranty for non-payment of invoice.

CONTACT FACTORY FOR COMPLETE PARTS
LIST FOR ALL MODELS.

KEEP THIS MANUAL FOR YOUR RECORDS.

Model Number: ______________________

Serial Number: ______________________

Date Purchased: _____________________

Dealer Purchased From: _______________

14716 S. Broadway St., Gardena, CA 90248

(310) 532–1555 ● [phone]

Fax: [phone]

Please go to our website at www.marsair.com for a

downloadable version of this document.

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