airmaster AM 150 User manual

1.2 .3
AM 150 .300 .500 .800 .900 .1000 .1200; AMC 150; DV 1000
INSTALLATION
CONNECTIONS .COMMUNICATION .COMMISSIONING

This Manual must be read before installing
the Airmaster air handling unit. Following
this Manual will ensure this product is oper-
ated correctly.
The installation contractor is responsible for
ensuring that the unit is installed according
to current regulations and standards.
When installing the air handling unit in a room
with a re or stove drawing air from the room,
all applicable provisions must be observed.
The unit should not be used in rooms with
abrasive particles or ammable or corrosive
gas in the air, in wet rooms (not CV-series) or
explosion-protected rooms.
The unit should not be used without the
lters specied in the Operator’s Manual.
The manufacturer cannot be held liable for
damage arising from use or installing in
contravention of these instructions.
The manufacturer reserves the right to make
changes without notice. All values stated
are nominal values and can be aected by
local conditions.
Failure to observe the warnings indicated by
a danger symbol implies a risk of personal
injury or damage to property.
This manual relates to the Airmaster unit it
accompanies plus all equipment, and must
be given to and saved by the unit’s owner.
All necessary data and guides to network
integration can be downloaded from www.
airmaster-as.com.
SAFETY INSTRUCTIONS
WARNINGS
Place of installation and serial numbers (S/N):
Type:
Delivery date:
Place of installation:
S/N of Air handling unit:
S/N of Cooling Module:
Service covers may not be opened without
rst disconnecting the unit’s power supply
and preventing use.
The unit may not be started up until all service
covers and grates on duct connections have
been installed.

Table of Contents
1. Technical Specications ................................................................................................................................5
2. Condensate Drain ...........................................................................................................................................7
3. Heating Surfaces ........................................................................................................................................... 8
3.1. Water Heating Surface ..................................................................................................................................................................................8
3.1.1. Bleeding...............................................................................................................................................................................................8
3.1.2. Setting the Line Regulating Valve............................................................................................................................................9
3.1.3. Frost Protection Valve ...................................................................................................................................................................9
3.1.4. Setting the Contol Valve...............................................................................................................................................................9
3.1.5. Check Heating Surface................................................................................................................................................................10
3.2. Electric Heating Surfaces ...........................................................................................................................................................................10
4. Electrical Installation ...................................................................................................................................11
4.1. Supply Voltage ................................................................................................................................................................................................ 11
4.2. Connection of Electrical Equipment....................................................................................................................................................... 11
4.2.1. Data Cable.........................................................................................................................................................................................12
4.2.2. Shield Termination........................................................................................................................................................................12
4.2.3. Control Panel....................................................................................................................................................................................12
4.2.4. Motion (PIR) Sensor......................................................................................................................................................................12
4.2.5. Carbon Dioxide (CO2) Sensor .....................................................................................................................................................13
4.2.6. External Stop Function................................................................................................................................................................13
4.2.7. External Start ..................................................................................................................................................................................13
4.2.8. Boost...................................................................................................................................................................................................13
4.2.9. Analogue BMS.................................................................................................................................................................................14
4.3. Checking Electrical Installation ................................................................................................................................................................14
5. Airlinq BMS Installation ...............................................................................................................................15
5.1. Connectors........................................................................................................................................................................................................15
5.2. DIP Switch / Jumper.......................................................................................................................................................................................15
5.3. Wiring-diagram for typical Airlinq BMS sytemes ..............................................................................................................................15
5.4. Junction Box for Group Control Panels...................................................................................................................................................15
5.5. System Programming...................................................................................................................................................................................16
5.5.1. Programming Units ID1 to ID19................................................................................................................................................17
5.5.2. Programming ID0. .........................................................................................................................................................................18
5.5.3. Programming Group Control Panels for Groups 1 to 19..................................................................................................19
5.5.4. Programming Cooling Modules ID1 to ID19........................................................................................................................ 20
6. Commissioning and Final Inspection ..........................................................................................................21
3

Appendix 1 Wiring Diagrams............................................................................................................................23
Control Box ..................................................................................................................................................................................................................... 23
AQC-L (Black Control Box) for AMC 150, AM 150, AM(L) 300, 500 and 800 ........................................................................ 23
AQC-P (Grey Control Box) for AM(P) 500, 800, 900 and 1200, AM(S) 1000 and DV 1000............................................ 23
AQC-C (Black Control Box) for Cooling Modules and AMC 150.................................................................................................... 23
DIP Switch and Jumper................................................................................................................................................................................ 23
Standard Connections AMC 150 with AQC-L (Black Control Box)............................................................................................................ 24
Standard Connections AM 150, 300, 500 and 800 with AQC-L (Black Control Box)....................................................................... 25
Standard Connections AM 500, 800 and 900 with AQC-P (Grey Control Box).................................................................................. 26
Standard Connections AM 1000 and 1200 with AQC-P (Grey Control Box).........................................................................................27
Connecting the AM 1000 Sections........................................................................................................................................................ 28
Connecting the AM 1200 Sections........................................................................................................................................................ 28
Standard Connections DV 1000 with AQC-P (Grey Control Box) ............................................................................................................. 29
Wiring Diagram for Typical Airlinq BMS Systems............................................................................................................................................ 30
Individual Units, One System Control Panel....................................................................................................................................... 30
Individual Units with Cooling Module, One System Control Panel............................................................................................ 30
Individual Units with Cooling Module and Group Control Panels, One System Control Panel ........................................31
Combined System ......................................................................................................................................................................................... 32
BMS Connections......................................................................................................................................................................................................... 33
LON®.............................................................................................................................................................................................................. 33
KNX®.............................................................................................................................................................................................................. 33
BACnetTM/IP ..................................................................................................................................................................................................... 34
BACnetTM MS/TP ............................................................................................................................................................................................ 35
MODBUS®RTU RS485................................................................................................................................................................................. 36
Airmaster Airlinq®Online (Ethernet) ....................................................................................................................................................................37
Appendix 2 Error Descriptions ........................................................................................................................ 38
4

5
m3/h 147 147 300 550 725
m3/h - - 270 490 688
m3/h 115 115 240 430 650
m 3,4 3,4 6,5 7,5 8,1
l/h 10 10 10 10 10
m 6 6 6 6 6
mm/mm 4/6 4/6 8/12 8/12 8/12
mm/mm - - 8/12 8/12 8/12
°C 75 75 75 75 75
°C 90 90 120 120 120
W - - 505 858 1379
°C - - 90 90 90
bar - - 10 10 10
- - 3/8”/DN10 1/2”/DN15
- -
s - - 60 60 60
V 1x230V+N+PE
Hz 50 50 50 50 50
W 38 48 100 132 156
A 0,3 0,4 0,6 1,1 1,1
0,55 0,52 0,56 0,58 0,56
W - 162 617 1038 1110
A - 1 3,8 6,4 6,8
- 0,7 0,7 0,71 0,71
W - 640 2450 3280 5240
W - 146 421 820 990
W 600 600 750/ 1500 - -
A 2,6 2,6 3,3/6,5 - -
W - - - 630 1000
A - - - 2,6 4,4
W - - - 1000 1500
A - - - 4,4 6,5
mA ≤0,5 ≤0,5 ≤3 ≤6 ≤6
mA - ≤1,5 ≤3 ≤2 ≤2
A 10 10 10 10 13
A 13 13 13 16 16
IP 10 10 10 10 10
1. Technical Specications
AM AMC AM AM AM
150 150 300 500 800
Max. ow rate with ePM10 75%/ePM10 75% lters at 35 dB(A)
Max. ow rate with ePM10 75%/ePM10 75% lters at 33 dB(A)
Max. ow rate with ePM10 75%/ePM10 75% lters at 30 dB(A)
Throw, max.
Condensate pump
Flow rate, max.
Pump head at ow rate 5 l/h
Drain hose air handling unit, int./ext. diameter
Drain hose cooling module, int./ext. diameter
Electric heating surface
Thermal cut-out, automatic reset
Thermal cut-out, manual reset
Water comfort heater
Power at 60/40°C Delivery/Return
Max. operating temperature
Max. operating pressure
Connections
Material Copper / aluminium
Motorised valve, opening and closing time
Electrical connection
Voltage
Frequency
Power consumption
Nominal current
Power factor
Cooling module power consumption, max.
Nominal current
Power factor
Cooling duty, nominal
Cooling duty, min.
Electric heating surface power consumption (VPH)
Nominal current
Electric comfort heater power consumption
Nominal current
Electric preheater power consumption
Nominal current
Max. leakage current on air handling unit
Max. leakage current on cooling module
Recommended fuse
Max. fuse
IP-Code
VPH: Virtual Preheat

6
m3/h 830 1100 1310 -
m3/h 760 1075 1180 -
m3/h 690 950 1050 -
m3/h - - - 1000
m 12 10,5 11 -
l/h 10 10 10 10
m 6 6 6 6
mm/mm 4/6 4/6 8/12 5/8
mm/mm - - - 8/12
°C 75 75 75 75
°C 120 120 120 120
   -
- - - 
W 2345 2540 2454 4099
°C 90 90 90 90
bar 10 10 10 10
1/2”/DN15
s 60 60 60 60
V 1x230V+N+PE 3x400V+N+PE
Hz 50 50 50 50
W 240 305 254 333
A 1,8 2,2 1,4 2,6
0,6 0,6 0,6 0,6
W - - - 1449
A - - - 8,9
- - - 0,71
W - - - 6450
W - - - 1120
W - - - 2500
A - - - 10,9
W 1050 1500 1670 -
A 4,4 6,5 7,3 -
W 1500 2300 2500 -
A 6,5 10 10,9 -
mA ≤6 ≤4 ≤9 ≤7
mA - - - ≤2
A 13 3 x 13 3 x 13 3 x 13
A16 3 x 16 3 x 16 3 x 16
IP 10 10 10 40
AM AM AM DV
900M (Mix.) 1000 1200 1000
Max. ow rate with ePM
10
75%/ePM
10
75% lters at 35 dB(A)
Max. ow rate with ePM
10
75%/ePM
10
75% lters at 33 dB(A)
Max. ow rate with ePM10 75%/ePM10 75% lters at 30 dB(A)
Nominal ow rate with ePM10 75%/ePM10 75% lters
Throw, max.
Condensate pump
Flow rate, max.
Pump head at ow rate 5 l/h
Drain hose air handling unit, int./ext. diameter
Drain hose cooling module, int./ext. diameter
Electric heating surface
Thermal cut-out, automatic reset
Thermal cut-out, manual reset
Water heating surface
Water comfort heater
Water heating surface, VPH (Virtual Preheat)
Power at 60/40°C Delivery/Return
Max. operating temperature
Max. operating pressure
Connections
Material Copper / aluminium
Motorised valve, opening and closing time
Electrical connection
Voltage
Frequency
Power consumption
Nominal current
Power factor
Cooling module power consumption, max.
Nominal current
Power factor
Cooling duty, nominal
Cooling duty, min.
Electric heating surface power consumption (VPH)
Nominal current
Electric comfort heater power consumption
Nominal current
Electric preheater power consumption
Nominal current
Max. leakage current on air handling unit
Max. leakage current on cooling module
Recommended fuse
Max. fuse
IP-Code
VPH: Virtual Preheat

7
Airmaster’s AM series is delivered either with a black control
box (AQC-L) or with a grey control box (AQC-P). The DV
series is always delivered with a grey control box (ACQ-P)
AM units with AQC-L:
AM 150, AMC 150
AM 300 (specic designation: AML 300)
AM 500 (specic designation: AML 500)
AM 800 (specic designation: AML 800)
AM units with AQC-P:
AM 500 (specic designation: AMP 500)
AM 800 (specic designation: AMP 800)
AM 900 (specic designation: AMP 900)
AM 1000 (specic designation: AMS 1000)
AM 1200 (specic designation: AMP 1200)
2. Condensate Drain
We recommend connecting the air handling unit’s (AHU)/
cooling module’s (CC) condensate drain to a wastewater
pipe from a condensate pump (1.) or directly from the
condensate tray (2.)
1. All air handling units and cooling modules with a
condensate pump:
AHU/CC
NB! Fit a water lock to avoid unpleasant odours from
the wastewater system.
AHU/CC


NB! The drain hose must not be subjected to negative
pressure or a downward incline of over 0.5 m.
The dimensions for the drain hose position can be found
under “Dimensional Drawings” and “Additional Dimensions”
in the installation manuals.
2. Air handling units without condensatpump (only
possible for AM 300, 500, 800 and 1200):
(16/20 mm hose)
AHU
NB! Fit a water lock to avoid unpleasant odours from
the wastewater system.
The dimensions for the drain hose position can be found
under “Dimensional Drawings” and “Additional Dimensions”
in the installation manuals.
Optional installation of condensate drain:
The hose can also be run through the outer wall. For this
version, drill a hole of suitable diameter and with a 1-2%
outward downward gradient.
NB! Remember to seal the gap between the hose and
outer wall.
NB! THE HOSE MUST BE PROTECTED AGAINST
FORMATION OF ICE.

8
3. Heating Surfaces
3.1. Water Heating Surface
The Airmaster air handling unit DV 1000 can be tted with
an external water heating surface. AM 300, 500, 800,
900, 1000 and 1200 can be tted with an internal water
heating surface.
The water heating surface for the DV 1000 is also used to
protect against the formation of ice in the heat exchanger.
The “Virtual Preheat” function is used for this purpose.
Further details are available in the Operator’s Manual.
For this option, a motorised valve and an automatic heat
retention thermostat are tted on the heating surface. The
water heating surface is leakage tested and nal inspection
performed according to standards and rules in eect.
The heating unit’s delivery ow is connected to the con-
nection tting marked FREM (“DELIVERY”) and the return
ow to the connection tting marked RETUR (“RETURN”).
NB! The dimensioning of pipes and valves and
connection of water to the unit must always be carried
out by an authorised specialist in accordance with
current legislation and regulations.
NB! There must be clean water in the installation for
the internal valves in the water comfort heater to be
able to function optimally without problems.
It is recommended that shut-o valves, a dirt lter and
a line regulating valve be tted in accordance with the
“External connection” block diagram. It is also recommended
to mount the bleed valve and drain cock for commissioning
and service.
It may be necessary (e.g. in the case of a district heating unit)
to install a pressure dierential regulator if the pressure
dierence ∆ps exceeds 40 kPa (10 kPa = 0,1 bar). If the
dierential pressure ∆p rises above the internal construction
above 40 kPa, the risk of noise from the control valve to the
heating surface increases.
External connection:
Δp
Δps
D
BC
G
A
E
TD
F
A Internal assembly (supplied by Airmaster).
B Shut-o valve (supplied by installation contractor).
C Dirt lter (supplied by installation contractor).
D Line regulating valve (supplied by installation contractor).
E Pressure dierential regulator (supplied by installation
contractor).
F Bleed valve (supplied by installation contractor).
G Drain cock (supplied by installation contractor).
Internal construction:
In the case of DV 1000, the internal assembly is installed on
the inside of the external heating surface. In the case of AM
products, the unit must be opened for any connection work.
M
TC
1
2
3
45
6
6
1 Return connection. (Delivery connection for the AM 800.)
2 Delivery connection. (Return connection for the AM 800.)
3 Frost protection valve (Comap D3803S) with remote
temperature sensor (Comap Senso RI).
4 Control valve (Comap D3803S) with electric On/O valve
(Ballerox 43600012).
5 Water heating surface.
6 Airow.
3.1.1. Bleeding
Open the water throughow and bleed the system using
the bleed valve (F). After a short time any air noise in the
water throughow should cease.
NB! The unit must be bled with fully open valves (3 + 4).

9
3.1.2. Setting the Line Regulating Valve
If a line regulating valve is installed, it must always be set
in the interval between minimum ow and maximum ow.
• It is recommended to set the line regulation valve
to a maximum ow according to the dierential
pressure of the heating system.
• The maximum ow is calculated using the largest
known dierential pressure in the system.
• The minimum ow is calculated using the smallest
known dierential pressure in the supply system.
• It is a prerequisite that the heat-bearing medium
in the system is raw water, with an anti-corrosive
agent added.
The following data applies to Airmaster’s heating surfaces:
Min. uid ow at
0,3 m/s (l/h)
Max. uid ow at
1,2 m/s (l/h)
AM 300 75 300
AM 500 75 300
AM 800 75 300
AM 900 120 480
AM 1000 135 540
AM 1200 120 480
DV 1000 340 1360
3.1.3. Frost Protection Valve
The sensor element (3 - TC) on the frost protection valve is
set to 8 °C (position in the middle between * and 1) to ensure
that the temperature according to the heating surface is
kept above 8 °C, and that the water in the heating surface
is free of frost. A prerequisite for this is that there is always
hot water available with a sucient dierential pressure.
NB! The heat supply or water ow must NEVER be
cut o or switched o in freezing temperatures, nor
when the air handling unit should be out of operation.
NB! The ow temperature must NEVER fall below 40°C
during periods of frost.
3.1.4. Setting the Contol Valve
The heating surface’s two valves are pre-set to 10 (com-
pletely open valve) when delivered. The freeze-protection
valve (3) must keep this setting unchanged.
The control valve (4) must be set to a value based on a critical
operation state. That is, the valve should not be limited to
the nominal ow, but must at least have “Minimum ow”
values available. When there is a high demand for heat,
the heating surface can therefore supply more than the
nominal values. On the other hand, cooling of the district
heating water is reduced.
The following data applies to Airmaster’s heating surfaces:
Nominal ow
(m3/h)
Min. uid ow
at 0,3 m/s (l/h)
Max. uid ow
at 1,2 m/s (l/h)
AM 300 300 75 300
AM 500 550 75 300
AM 800 725 75 300
AM 900 830 120 480
AM 1000 1100 135 540
AM 1200 1310 120 480
DV 1000 1000 340 1360
The valve can be set according to the calculations below
and the graph so that the required ow can be achieved
with the dierential ow of ∆ps that is available.
NB! The system must be bled before it is adjusted.
Parameters used in the calculation example:
OT Lowest outside temperature (°C)
RT Ambient temperature (°C)
 Minimum eciency of heat exchanger (%)
IT Desired inlet temperature (°C)
VLInlet airow (m3/h)
tFWater temperature DELIVERY (°C)
tRWater temperature RETURN (°C)
∆p Desired dierential pressure: 20-40 kPa,
preferably around 30 kPa (10 kPa = 0.1 bar)
1. Calculate temperature (t) according to heat
exchanger. [°C]
2. Calculate heating requirement (Q) for heating the
air to the desired inlet temperature. [W]

10
3. Calculate the desired water quantity (VV). [l/h]
4. Use the diagram to nd the setting point for the
control valve (4).
[l/h]
10
(A)
20
30
40
50
100
500
1000
[kPa] [kV]
1
10
(B)
100
2
3
4
5
6
7
8
9
20
30
40
50
60
70
80
90
1
(C)
2 3 4 5 6
7
8
9
10
• Plot the calculated water quantity (A) on the dia-
gram. (Here VV = 150 l/h)
• Plot the desired dierential pressure for the control
valve (B) on the diagram. Here, ∆p = 30 kPa. (The
optimal value for the valve is between 20 and 40
kPa.)
• Use the diagonal lines to read o the value (C) for
the valve setting.
• Set the valve to the calculated value using the
presetting key. (In this example the control valve
is set to 4,5.)
Nominal ow and heat output apply to a winter state in
which:
• The outdoor air is = -12 °C, 90% relative air humidity.
• The indoor air is = 22 °C, 20% relative air humidity.
• The heating supply’s ow temperature is = 60 °C.
Nominal ow
(m3/h)
Nominal
power (W)
Nominal uid
ow (l/h)
AM 300 300 505 19
AM 500 550 858 53
AM 800 725 1379 60
AM 900 830 2345 111
AM 1000 1100 2540 112
AM 1200 1310 2454 107
DV 1000 1000 4099 180
3.1.5. Check Heating Surface
yes no
Water pipes connected correctly to heating plant
Heating surface is bled
Heating surface is waterproof
Frost protection valve adjusted to
Control valve adjusted to
Line regulating valve
installed and adjusted to
Pressure dierential regulator
installed and adjusted to
Name of installation engineer:
Comment:
3.2. Electric Heating Surfaces
Airmaster units can be supplied with one or two built-in
electric heating surfaces. In such cases, the safety ther-
mostats are installed inside the unit.
Electric heating surfaces for AMC 150, AM 150, AM 300
and DV 1000 are installed as comfort heaters but are also
used to protect against the formation of ice in the heat
exchanger. The “Virtual Preheat” function is used for this
purpose. See the Operator’s Manual.
NB! Electric heating surfaces consume more power.
For further details, see “Technical Specications”.
Safety functions on an electric heating surfaces:
The electric heating surfaces are protected against
overheating by two safety thermostats for each heating
surface, which disconnect the heating surfaces in the event
of overheating.
The safety thermostats are installed in the heating surface.
• One of the thermostats disconnects the heating
surface and is equipped with an automatic reset.
For further details, see “Technical Specications”.
• The second thermostat also disconnects the heating
surface but is equipped with a manual reset. For
further details, see “Technical Specications”.