CLAUDGEN CA1309S10 Screen Zone Commercial Air Curtains User Manual

CLAUDGEN CA1309S10 Screen Zone Commercial Air Curtains

All electrical appliances produced by the Company are guaranteed for one year against faulty materials or workmanship. This applies only if the appliance has been used for purposes in accordance with the instructions provided and has not been connected to an unsuitable electricity supply, or subject to misuse, neglect, damage or modified or repaired by any person not authorised by us. This guarantee is offered to you as an extra benefit and does not affect your legal rights.
The correct electricity supply voltage is shown on the rating label attached to the appliance.
Reasonable care has been taken to ensure that this guide is accurate at the time of printing.
In the interest of progress the Company reserve the right to vary specifications from time to time without notice.

General Information

Warnings
All installations must be in accordance with the regulations. These instructions must be handed to the user on completion of the installation. Installers and ser-vice engineers must be able to demonstrate competence and be suitably qualified in accordance with the regula-tions. To ensure continued and safe op-eration it is recommended that the ap-pliance is serviced annually. The air cur-tain outlet/inlet grille must not be ob-structed during use. Any modifications made to the unit not approved by Con-sort will void the manufacturer’s warranty and potentially create a hazard. The appli-ance is NOT intended for use by persons (including children) with reduced physi-cal, sensory or mental capabilities or lack of experience or knowledge unless they have been given instruction concerning use of the appliance by a person re- sponsible for their safety. Children should be supervised to ensure that they do not play with the appliance. Parts of the heater can become very hot when in operation and cause burns. The heater is not equipped with room thermostat and should not be used in small rooms so as to avoid overheating.

Health and Safety
Please read this instruction thoroughly before installing the appliance. Sole liability rests with the installer to ensure that all site safety procedures are adhered to during installation. Sole liability rests with the installer to ensure that protective safety wear such as hand, eye, ear and head protection is used during the installation of the prod-uct. Ensure that all anchoring points are suitable for the weight of the appliance.

Electrical Supply
This heater must be permanently connected to the electricity supply via a double pole switch having 3mm gap on each pole. There are no exceptions.
All units must be wired in accordance with I.E.E. regulations for the Electrical Equipment of Buildings.
BMS control, time switches and door interlocks can be installed at the discretion and responsi-bility of the installer.
Follow paragraph 4 ‘technical specification’ for more details.

Location
All units should be installed directly over the door opening. It is recommended that the air curtain is installed on the inside of the building.
Care must be taken to allow complete free air movement into the inlet grilles of the unit to ensure correct working operation of the air cur-tain. The discharge opening should be as close to the top of the door as possible and cover the entire door width. Units can be mounted adjacent to each other to cover the full door opening across wider en-trances.

Clearance Distance
It is recommended that a minimum clearance of 50mm is allowed above the heater. The clearance allows for cable entry and addition-al air inlet. It also prevents surfaces overheat-ing.
The minimum mounting height (floor to grille) is 2m. The maximum mounting height is 3.4m.

Standards

• The heater conforms to the following standards
• Electrical Equipment (Safety) Regulations 2016 SI. 2016 1101
• Electromagnetic Compatibility Regulations 2016 SI. 2016 No. 1091
• Radio Equipment Regulations 2017 SI. 2017 No. 1206
• The Ecodesign for Energy Related Products and Energy Information (Amendment) (EU Exit) Regulations 2019. SI. 2010 2617
• The Restriction of use of Certain Hazardous Substances. SI. 2012 No. 3032
• The Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597)

Introduction

Introduction
This instruction manual describes the Screen-Zone Commercial range of air curtains. They are designed for discreet positioning above the doorways of retail or commercial prem-ises up to 3.4m ceiling height.
The air curtains comprise multiple modular blower units 510mm or 615mm wide and with nominal maximum power output from 4.5kW to 7kW 3Ph 415V. Models are available in 1.3m, 1.5m and 2m lengths, made up of 2 or 3 blower units. For wider doorways, up to 7 air curtains can be easily interconnected using CAT5/CAT6 RJ45 networking cable It is recommended that this control cable is run separately within its own trunking to avoid external interference. The air curtain can be controlled by option-al Touchscreen controller (not supplied with the heater) , mechanical switches or BMS.

• WARNING:
  THIS AIR CURTAIN SHOULD NOT BE INSTALLED WHERE THERE IS A CORROSIVE ATMOSPHERE OR EX-ESIVE DUST.

Mechanical switch Controller
Each air curtain is supplied with HE8408 me-chanical switch. More details at Installer wiring section. This controller will provide 2 fan speed and 3 heat setting options.

Optional Color Touchscreen Controller

Optional Color touch screen controller (not supplied with the heater) giving options for 8 fan and 8 heat settings can be mounted up to 50m from the air curtain. Optional BMS control, remote thermostats and door interlocks can be installed. The electronic touch screen controller shown on the picture below allows the user to control either a single air curtain, or a network of up to 7 air curtains with the same settings. The controller is designed to be mounted on a surface double gang back box, and is pow-ered by an RJ45 connection. The controller will not fit metal or dry lining back box. The cable length between the base unit and the controller can be up to 50 metres.

Dimensions & Fixing locations

Air Curtain Dimensions

1. Keyholes for 06mm fixings
2. Holes for 010mm fixings
3. Holes for 06mm fixings
4. 020mm knock-outs
5. M8 threaded fixings

Technical Specifications

Wiring Details

Installer Wiring

Factory Wiring

Network Wiring – Controller

• CAT5 cable with RJ45 connectors can be used to network up to 7 air curtains in a daisy-chain configuration.
• The DIP switches 1, 2 and 3 are used to configure each air curtain with a unique address.
• DIP switch setting 000X is reserved for when a controller or BMS is not used.
• E.g. air curtain 1 DIP switches set to 1000.
• External and door switches are connected between COM and SW1 or SW2.
• Their behaviour can be configured in the controller settings menu.

Network Wiring – Switches

• The aircurtain can be also controlled by mechanical switches.
• In this configuration touchscreen controller or BMS controls will not work.
• To operate heater by mechanical switch-es, the DIP switches on the main pcb need to be set to 000X.
• The DIP switch 4 is used to select fan speed range.
• For installation height of 2 – 3m set the DIP switches to 0000.
• For installation height of 3 – 4m set the DIP switches to 0001.
• SW1 – on / off
• SW2 – low speed / high speed
• SW3 – 1/3 heat output
• SW4 – 2/3 heat output
  

Modification for use on single phase (CA1309 only)

CA1309 is supplied as 3 phase only appliance. In order to use it with a single phase sup-ply, the internal wiring has to be modified. The appliance is supplied with a single phase conversion kit. The pictures below describe how to change the internal wiring. After the internal wiring has been modified it is necessary to change labelling of the connector as shown on the picture below and also new rating label showing single phase supply must be use to cover the existing 3 phase operation rating label.
This has to be followed exactly. Internal wiring of the heating element for 3 phase operation

Modification of internal wiring of the heating element for single phase operation

Modification for use on single phase (CA1309 only)

Installation Details

Screw location for grille removal Mounting

All units should be installed horizontally directly over the door opening. It is recommended that the air curtain is installed on the inside of the building, within the open room space against a wall or ceil-ing.
Care must be taken to allow complete free air movement into the inlet grilles of the unit to ensure correct working operation of the air curtain. The discharge opening should be as close to the top of the door as possible and must cover the entire door width.
Units can be mounted adjacent to each other to cover the full door opening across wider entranc-es.

Electrical Supply
The cable entry is located on the top centre of the heater. Cable entry is located on a removable bracket for easier installation. The heater is supplied with two 20mm cable glands. The cable gland holes can be enlarged by removing excess metal to 25mm. The bracket is secured by two hex head screws.

Installation
It is the sole responsibility of the installer to ensure that the points of attachment to the building are sound. Consultation with the consultant/architect or owner of the building is recommended to ensure that a sound, mechanically stable installation is achieved.
All attachments must be capable of supporting the weight of the product.

1. Step
   Carefully unpack the heater.

2. Step
   Remove the grille by loosening screws as shown on the picture above.

3. Step
   For wall mounting:
   The heater can be fixed to the wall using 6mm or 10mm holes provided.
   Mark and drill required holes as explained in section 3 and fix heater to the wall.
   For suspending from the ceiling:
   Either drop rods or catenary wire can be used to fasten the air curtain to the ceiling support structure. The mounting points can be seen in section 3.

4. Step
   Remove cable entry bracket.
   Connect electrical supply , optional door switches and external sensor to appropriate terminals and reattach the bracket.

5. Step
   Test the heater.

6. Step
   Refit the heater grille.

Fault detection and LEDs

Fault detection

• When the air curtains are powered up in standby mode, a green LED on the main

• board shows that the 12V power supply is working correctly:
  When heat or cold blow is demanded the secondary PCBs are powered. A second

• LED on the main PCB shows that the second 12V power supply is working correctly:

• A fault with the auxiliary power is indicated by a flashing orange LED on the main PCB:

• A green LED on the secondary PCBs shows that they are receiving 12V power:

• The air curtain monitors the fan speed, power output and heatsink temperature. In the event of a fault the red LED on the sec-ondary PCB flashes:

The red LED flashes a number of times and then pauses. The number of flashes de-notes the fault.

Over heat protection reset
The heater is equipped with electronic over heat protection and also manually resetta-ble over temperature cut-outs. There are two cut-outs on each blower module on the top of the heating element. The CA13 and CA15 heaters have four cut-outs in to-tal and CA20 six cut-outs. In the unlikely event of electronic failure, the mechanical cut-outs will switch off power to the heating element. In order to reset cut-outs, isolate the heater from power and press small plastic push button on the top of each cut-out. The cause of cut-outs operating should be investigated before resetting.

BMS Connection MODBUS Protocol

BMS Connection
The heater is compatible with BMS systems using MODBUS protocol.
The connection to BMS system can be made using one of the RJ45 connectors.

Only one means of control can be used at any time. If BMS is used to control the heater, the colour screen controller must not be used. The BMS can control fan speed and heat output and also read and report the heater status. Speed can be set in the range of 600 – 1700RPM in 1RPM steps. If the speed is set below 600RMP, the heating element is automatically disabled. Care has to be taken when selecting speed. The fan speed should be always correct for the selected heat output. If the speed is too low, the heater can overheat. Heat output can be set in the range of 0 – 100% in 1% steps.

MODBUS Protocol

The DIP switches 1, 2 and 3 are used to configure each air curtain with a unique address.

RJ45 cable can be used to network up to 7 air cur-tains in a daisy-chain configuration.
DIP switch setting 000X is reserved for when a con-troller or BMS is not used.
All possible addresses:

• RS485 serial half-duplex interface
• MODBUS RTU
• 9600 baud
• 8 bits
• 1 start bit
• no parity + 2 stop bits
• ‘mark’ parity + 1 stop bit

Supported MODBUS function codes:

• 0x03 read multiple input registers
• 0x04 read multiple holding registers
• 0x06 write single holding register
• 0x10 write multiple holding registers

16 Bit Input Registers:

1. Status
2. Temp 1
3. Temp 2
4. Temp Heatsink
5. Temp External
6. External Switches

Temperatures are formatted as 16 bit signed integers. Units are sixteenths of a degrees Celsius, as used by DS18B20 temperature sensors. The hex value 0xF000 is used to denote an invalid reading.
The status register uses bits to indicate faults:

• Bit 0 – overheat
• Bit 1 – heatsink overheat
• Bit 2 – temp sensor 1
• Bit 3 – temp sensor 2
• Bit 4 – heatsink temp sensor
• Bit 5 – remote temp sensor
• Bit 6 – L2 on current low
• Bit 7 – L2 off current high
• Bit 8 – L3 on current low
• Bit 9 – L3 off current high
• Bit 10 – motor PSU
• Bit 11 – motor
• Bit 12 – MCU
• Bit 13 – connection
• Bit 14 – 12V auxiliary power
• Bit 15 – main PCB relay
• External switches register uses bits to show the state of switches:
• Bit 0 – Switch 1
• Bit 1 – Switch 2
• Bi2 – Switch 3
• Bit 3 – Switch 4

16 Bit Holding Registers:

1. RPM (units revolutions per minute)
2. Power (units percentage 0 –100)
   RPM must be set to at least 600, otherwise heating is disabled.

Touchscreen Controller Operation

Home Screen

The home screen provides information about the heater status and all relevant functions.

• Time
• Operating mode
• Heater status
• Door switch status
• Timer status
• Heat output
• Fan speed
• ON / Stand-by button
• Settings menu button

Settings menu

All functions and settings are available from this menu.
Time

The time can be set using the arrow buttons. A coin battery CR1220 maintains the time when power is interrupted. Time is displayed on the home screen and needs to be set to use the timer function.

Lock

PIN function can be enabled to prevent unwant-ed operation of the heater or changing the set-tings.
The PIN can be completely disabled, enabled for settings only or all functions.
The default Pin is set as 1234, but can be changed using the Change Pin button. If the PIN is forgotten contact Consort technical help.
Timer

The 7 day timer function allows scheduling auto-matic switching between on and stand-by. Each day can be individually enabled or disabled. The timer allows up to two periods of operation per day. The white bars indicate when the heater is timed to switch on.
Use the settings buttons to set up the time for each day (see next page), and the copy button to copy settings from one day to another.

Touchscreen Controller Operation – cont

Timer – time schedule

There are 2 timer periods for each day available. Tapping the slider in the top right corner will change between 1 or 2 time periods.
The times for the first time periods are on the top of the screen, the times for the second timer period are on the bottom of the screen. Times can be ad- justed in 15 minute intervals using the buttons.
When the timer is active, an icon will appear on the home screen giving information about the next switch time.
External switches

There is a provision for 2 remote switches than can be wired into the air curtain with. The switches must be voltage free type, NO or NC configuration.
SW1 can be connected to a door switch or occu-pancy sensor installed in the door area. When the function is activated, the door switch will enable the air curtain when the door is open and disable it when the door is closed. The second slider is used to configure the system for the correct switch type. When the air curtain is disabled by the door switch, the heater will operate at a low fan speed. This will allow for a fast start-up when the door is opened. When SW1 is active, the home screen will show the status of the door switch.
SW2 is intended for a remote switch that can be used to disable the air curtain from a remote loca-tion. Usually this would be a simple BMS or external timer connection. Once disabled using remote switch the air curtain can’t be controller by the touchscreen controller and will remain disabled until enabled remotely.

Operating Mode selection

One of four operating modes can be selected. Each mode uses a different method of select-ing heat and fan settings when the air curtain is not in stand-by mode. Use the settings button to configure each mode.

Manual Mode

In manual mode user can select required fan and heat output by tapping + or – symbols on the home screen next to the fan and heat bars.

There are 8 fan speeds and 8 heat settings available. It is possible set maximum and mini-mum limits for fan speed and heat output. Once limits are set and functions activated, only limited fan speed and heat output will be available on home screen when in manual mode.

Automatic Mode

Automatic Mode is the best choice for easy to set-up efficiency and comfort. Set the height by moving slider to the required position. The air cur-tain will run at optimum fan speed and heat out-put based on the inlet temperature.
Temperature Mode 1

Temperature Mode 1 is very similar to Automatic Mode, with the addition of having an option for adjusting the airflow temperature. With the air-flow temperature set in the middle of the scale, this is equivalent to Automatic Mode.
In certain situations, when required, airflow can be increased or decreased by increasing or de-creasing the set installation height. Using a higher setting for the installation height will make the air curtain less energy efficient.

Temperature Mode 2

This operating mode is suitable for situations where the heater is used to maintain the room temperature or where the requirement is to ad-just the heat output based on the indoor/outdoor temperature.
This operating mode can use either the internal or supplied external temperature sensor.

The temperature on the left defines the starting point below which the air curtain uses full power. The temperature on the right defines the point above which the air curtain doesn’t produce any heat. As the measured temperature rises the heat output is gradually reduced until heater doesn’t produce any heat. Using the internal temperature, this mode can be used to maintain room temperature. With remote sensor installed outside, this mode can be used to compensate for external temper-ature. There is also an option to select fan function after the heater stops producing heat. Fan can be set to turn off after the heater stops producing heat or run all the time.

Heater status

The Status screen provides an overview of values from all connected heaters. The heaters need to be run before some of the values can be calcu-lated.
In the event of a fault a red warning triangle is displayed:

More details are available when tapping the details button. The detailed status screens are primarily for installers or engineers to help with installation or fault diagnostics.

The connected heaters screen shows all of the currently connected heaters, in order of address ID. Heaters are connected when the controller is first powered up. In order to connect to newly powered heaters, press Refresh to search for heaters.
For each connected heater, up to 3 detailed status screens are available. These are general status, faults and sensor screens.
The links to the faults and sensor screens are hid-den when no faults have been identified.

Heater status – cont.

The general status screen shows details about the heater and all of the internal blower units. The heater needs to be run before some of the values can be calculated.
The faults screen can provide detailed diagnos-tics of faults for each internal blower unit.
The sensor screen shows the status of the tem-perature sensors.
Energy usage

The energy usage screen provides information related to energy used from the day the heater was installed. The values are calculated based 3PH 400V and so will differ from actual energy usage when mains voltage is lower or higher.
Identification

User can set ID number for controller identifica-tion. This number is shown on the left hand cor-ner of the home screen. This feature is useful in situation where there are more than one control-ler side by side.

Declaration Of Conformity

• In accordance with UK Government Guidance.
• WE HEREBY CERTIFY THAT THE APPLIANCES DETAILED HEREON HAVE BEEN
• INSPECTED AND TESTED, AND CONFORM TO THE REQUIREMENTS OF THE FOLLOWING UK STATUTORY INSTRUMENTS WHERE APPLICABLE:
• Electrical Equipment (Safety) Regulations 2016 SI. 2016 1101
• Electromagnetic Compatibility Regulations 2016 SI. 2016 No. 1091
• Radio Equipment Regulations 2017 SI. 2017 No. 1206
• The Ecodesign for Energy Related Products and Energy Information (Amendment) (EU Exit) Regulations 2019. SI. 2010 2617
• The Restriction of use of Certain Hazardous Substances. SI. 2012 No. 3032
• The Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597)

Transposed standards used

• BSEN55014 (2006)
• BSEN301 489.1 & .3
• BSEN300 220.1 & .2
• BSEN60 730.2.9
• BSEN 60335.1 (2012 )
• BS EN 60335.2.30 (2009)

PART NUMBER AND DESCRIPTION OF APPLIANCE: RAC10HL, RAC15HL, RAC20HL AIRCURTAINS

NAME OF RESPONSIBLE PERSON: A C REYNOLDS
POSITION: QUALITY ENGINEERING
DATE : 22/03/21

CONSORT EQUIPMENT PRODUCTS LTD.
THORNTON INDUSTRIAL ESTATE, MILFORD HAVEN, PEMBROKESHIRE, SA73 2RT. UK
TEL: +44 1646 692132 FAX: +44 1646 695195. E-MAIL: ENQUIRIES@CONSORTEPL.COM WWW.CONSORTEPL.COM

References

• Consort Claudgen - Electric Heating Solutions

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