Berner DIPLOMAT DP21036 Installation and operating instructions

1
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 manufac-
turer.
B. Before servicing or cleaning unit, switch power off at the service panel and lock service panel to prevent power
from being switched on accidentally.
C. Installation work and electrical wiring must be done by qualified person(s) in accordance with all applicable codes
and standards, including fire-rated construction.
D. When cutting or drilling into wall or ceiling, do not damage electrical wiring and other hidden utilities.
E. Do not operate this fan with any solid state speed control device.
F. Sufficient air is needed for proper combustion and exhausting of gases through the flue (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 Heat-
ing, Refrigeration and Air Conditioning Engineers (ASHRAE), and local code authorities.
UNCRATING
Carefully examine the carton(s) for damage before opening. If
the carton is damaged, immediately notify the shipping com-
pany. Open the carton and remove all protective packing.
Remove the unit by lifting vertically. Place the unit upside
down on end supports to avoid damage to the electrical junc-
tion box. If the unit will be wall mounted, remove and save the
two (2) locking screws from the back corners and detach the
wall mounting plate. See Figure 1.
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THESE INSTRUCTIONSTHESE INSTRUCTIONS
THESE INSTRUCTIONSTHESE INSTRUCTIONS
THESE INSTRUCTIONS
No.: II-260
Date: November, 2005
Installation &
Maintenance Instructions
BERNER INTERNATIONAL CORPORATION
New Castle, Pennsylvania
724-658-3551 ● 1-800-245-4455 ● www.berner.com ● [e-mail]
© Copyright 2005 Berner International Corporation
The DIPLOMAT/MARK II air door is designed to be an effec-
tive barrier against cold drafts in the winter and hot humid air in
the summer. To achieve optimum protection, the unit should
be mounted on the inside of the building, flush to the wall (do
not obstruct the nozzle or air stream) and as close to the top
of the door opening as possible. See Figure 2.

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WALL PREPARATION
1. Position and center the mounting plate over the door
opening. The mounting plate must be positioned with the
45° lip and the rubber vibration gasket on top. Four (4)
slotted mounting holes are provided on the mounting
plate. See Figure 4.
2. Mark the wall in the center of each mounting plate hole.
The wall must provide sufficient support for the air door.
The mounting hardware (supplied by others) must be
capable of supporting a minimum of three times the net
weight of the air door. See Weight Chart, Table 1. If the
location of the marks on the wall do not provide suitable
support, mark and drill additional holes.
3. Drill the four holes as marked on the wall and attach the
mounting plate with anchors (if used) and the four
mounting screws (provided by others).
INDOOR INSTALLATION - WALL MOUNTING
For maximum efficiency, the unit should be mounted no
higher than 8’0” above the floor.
1. Install the DIPLOMAT/MARK II Series Air Door so that
nothing interferes with the curtain of air when it is
deflected 20° to either side. If the air stream strikes any
obstruction, i.e. the top edge of the doorway, a structural
beam, a door opening device, etc., its efficiency will be
greatly reduced. See Figure 2.
2. The lower lip of the mounting plate should be no more
than 1” above the door open- ing when the unit is
mounted flush to the wall. If the air door 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
the best performance, any void between the air door and
the wall must be sealed (use foam, plastics or a similar
packing). See Figure 3.
3. Do not block the air flow to or from the unit since this
could cause overheating. On electrically heated units
there should be:
A) a minimum clearance of at least 4” between the side
of the unit and any combustible material if the unit is
enclosed in the ceiling or a decorative cover.
B) a minimum clearance of 8” between the top of the
unit and the ceiling in order to service the junction
box(es).
C) do not install less than six feet (or 1.8 meters) from
the floor to the unit. See Figure 2.
Figure 3
Table 1
Figure 1
Figure 2
Model Unheated Electric Hot Water/Steam
DP2/MK21036 100 110 120
DP2/MK21042 118 125 140
DP2/MK21048 125 132 155
DP2/MK22048 138 140 197
DP2/MK22060 160 179 210
DP2/MK22072 174 219 222
DP2/MK22084 195 254 227
DP2/MK22096 210 275 235
DP2/MK23096 216 284 240
DP2/MK23108 237 305 248
DP2/MK23120 268 324 270
WEIGHT IN POUNDS

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ATTACHINGTHE AIR DOORTOTHE MOUNTING PLATE
1. Raise the unit over the door (air discharge nozzle facing
down) and on to the mounting plate. First, tilt the unit
upward matching the top recessed edge of the unit to the
top 45° angled lip on the mounting plate. See Figure 5.
2. Lower the unit into place, allowing it to rest on the lower lip
of the mounting plate.
3. After the unit is securely attached to the mounting plate,
re-install the two (2) locking screws at the bottom corners.
See Figure 5.
INDOOR INSTALLATION:TOP MOUNTING (CEILING
SUSPENSION)
For top mounting suspension rods, four (4) factory installed
5/16” threaded inserts are located on the top of the unit.
See Figure 6.
1. Install the DIPLOMAT/MARK II Series Air Door so that
nothing interferes with the curtain of air when it is de-
flected 20° to either side. If the air stream strikes any
obstruction, i.e. the top edge of the doorway, a structural
beam, a door opening device, etc., its efficiency will be
greatly reduced. See Figure 2.
2. Follow instructions 2 and 3 under INDOOR INSTALLA-
TION:WALL MOUNTING (on page 1) checking to assure
the minimum clearances are met.
3. Attach 5/16” threaded rods, or other suitable hardware to
the top mounted threaded inserts.
Figure 4
Table 2
Table 3
Figure 5 Figure 6
120 V
1ø
208/240 V
1ø
460 V*
1 ø
Motor
Amps
Motor
Amps
Motor
Amps
DP2/MK21036 1@½ 7.2 4.0 1.3
DP2/MK21042 1@½ 7.2 4.0 1.3
DP2/MK21048 1@½ 7.2 4.0 1.3
DP2/MK22048 2@½ 14.4 8.0 2.6
DP2/MK22060 2@½ 14.4 8.0 2.6
DP2/MK22072 2@½ 14.4 8.0 2.6
DP2/MK22084 2@½ 14.4 8.0 2.6
DP2/MK22096 2@½ 14.4 8.0 2.6
DP2/MK23096 3@½ 21.6 12.0 3.9
DP2/MK23108 3@½ 21.6 12.0 3.9
DP2/MK23120 3@½ 21.6 12.0 3.9
MOTOR DATA
Model #Motors
@HP
*Special 1/3 hp Two Speed Motor
MODEL KW
460V 3Ø**
Amp Draw
Circuit 1
600V 3Ø**
Amp Draw
Circuit 1
DP2/MK21036 9.5 45.7 - 39.6 - 26.4 - - 22.9 - 11.4 9.5
DP2/MK21042 9.5 45.7 - 39.6 - 26.4 - - 22.9 - 11.4 9.5
DP2/MK21048 9.5 45.7 - 39.6 - 26.4 - - 22.9 - 11.4 9.5
DP2/MK22048 12.5 20.0 40.1 17.4 34.7 34.7 - - 30.1 - 15.0 12.6
DP2/MK22060 16.0 - - - - 44.4 - - 38.5 - 19.2 16.1
DP2/MK22072 19.0 - - - - 26.4 26.4 - 22.9 22.9 22.9 19.1
DP2/MK22084 19.0 - - - - 26.4 26.4 - 22.9 22.9 22.9 19.1
DP2/MK22096 19.0 - - - - 26.4 26.4 - 22.9 22.9 22.9 19.1
DP2/MK23096 25.0 - - - - 34.7 34.7 - 30.1 30.1 30.1 25.1
DP2MK23108 28.5 - - - - 26.4 26.4 26.4 22.9 45.7 34.3 28.6
DP2/MK23120 28.5 - - - - 26.4 26.4 26.4 22.9 45.7 34.3 28.6
ELECTRIC HEATER DATA*
Add total motor amp draw from Table #2 to circuit #1 for unit total amp draw
*Optional kW available. Check wiring diagram supplied with unit for kW and AMP draw if not listed above.
** Separate 120V, 208V or 240V single phase circuit required to operate motors.
240V 3Ø Amp Draw
Circuit 1 Circuit 2
208V 1Ø
Circuit 1
Circuit 2
240V 1Ø
Circuit 1
Circuit 2
208V 3Ø Amp Draw
Circuit 1 Circuit 2 Circuit 3

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AIR DIRECTIONAL VANES
1. Loosen the two (2) nuts on each end of the outlet nozzle.
Adjust the air directional vanes so the air flow split is in the
proper location. See Figure 10.
2. Retighten the two screws after air directional adjustment is
complete.
ELECTRIC WIRING
All electrical wiring should be done in accordance with local
codes and regulations.
MAKE SURE THE CORRECT VOLTAGE AS MARKED ON
THE UNIT IS USED.
The DIPLOMAT/MARK II air door is internally wired to the junc-
tion box(es) on top of the of the unit.
1.Run the proper size cable from the source to the junction box
and connect the leads.
2.Wiring diagrams are located inside the junction box. For
amp rating, see Tables 2 or 3 and the name plate on the unit.
ADJUSTMENTS
AIR FLOW ADJUSTMENTS
1. With the air door operating and the door in its full open
position, check to see that nothing is obstructing the air
flow at the discharge nozzle.
2. Find the air stream split location. Hold a handkerchief,
by its corners, approximately 12” above the floor. Gently
move the handkerchief back and forth in the doorway.
Make sure the air is being directed to both the inside and
the outside. See Figure 9. The split location is indicated
where the handkerchief is vertical with minimal or no
fluttering.
3. The split location should be approximately 3” outside the
doorway and 12” above the floor.
If the split location does not conform to the above specifica-
tions, the air directional vanes in the
outlet nozzle should be adjusted.
Figure 7 Figure 8
ELECTRICALLY HEATED MODELS
The heater circuit may be controlled by a remote thermostat,
a built-in thermostat or a manual on/off heater switch located
on the discharge side of the unit. See Figure 7.
1. If a thermostat is used, connect the proper leads located in
the junction box to the leads of the thermostat. (See wiring
diagram located in the junction box)
2. If a manual heat on/off switch is used, factory wiring is
supplied from the heating coil to the unit mounted heat on/
off switch.
Overheat protection is provided by thermal cutouts built into
the heater coil assembly. (See the wiring diagram located in
the junction box.)
STEAM OR HOT WATER HEATED MODELS
Piping should be done in accordance with local codes, regula-
tions and standard practice.
1. Connect the supply & return to the 1” MPT nipples on the
heating coil. See Figure 8.
2. Temperature controls to be supplied by others.
MAINTENANCE AND CLEANING
WARNING: Before servicing or cleaning the unit, switch
the power off at the service panel and lock the service
panel to prevent the power from being switched on
accidentally.
To keep your air door operating at peak efficiency, the
blower wheels, housings, motor(s) and intake grille must be
kept free of dust and debris. 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 weeks. If the environment is
not that dirty, the unit(s) should be scheduled for cleaning a
minimum of once every (3) months. Contact your mainte-
nance department to schedule your unit for periodic clean-
ing when the air door is installed.
To access the interior of the unit:
1. Remove the intake grille by removing the locking screw
on each end of the unit. Lift the intake grille up and then
towards you.
2. Remove the bottom access panel. Remove Phillips
head screws on the bottom of the unit.
Vacuum and scrape (if necessary) to remove the build-up of
dirt and debris. The motor(s) are permanently lubricated
and require no additional lubrication. Re-install the cover
and intake grille.
IMPORTANT: Reconnect the power source after cleaning.
Use this unit only in the manner intended by the manufac-
turer. If you have any questions, contact the manufacturer.
Figure 9 Figure 10
Figure 11

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• Air stream too weak
• Air steam hits obstruction
• Negative pressure
• Shaft rotating inside fan
• One motor not operating
• Nozzle not angled out far enough
• Unit too powerful
• Air movement too cold
• Pushing air outside building
SEE AIR IS NOT HITTING FLOOR SYMPTOMS
• Switch turned to “ON” position
• Thermostat not set properly
• Coils burned out due to lack of air
• Automatic reset thermal cutout failed in open position
• Manual reset thermal cutout tripped (if supplied)
• Speed sensor not detecting trigger rotation
• Without speed adjustment, failed speed sensor
• Adjust nozzle to proper position, adjust motor speed; see
installation instructions
• Remove obstruction or reposition air curtain (move out
3/8” for every 1” up from the door)
• Relieve negative pressure by providing makeup air
• Tighten set screws
• Repair or replace motor
• Adjust nozzle angle to outside
• Adjust motor speed
• Add auxiliary heat to overcome wind chill factor
• Adjust discharge angle back into building, adjust motor
speed
• Replace switch or check wiring
• Change thermostat setting
• Correct airflow problem; replace coils
• Replace automatic thermal cutout
• Reset manual thermal cutout
• Adjust gap between sensor and trigger
• Replace speed sensor
AIR IS NOT HITTING
FLOOR
UNEVEN AIR
EXCESSIVE AIR
MOVEMENT AT DOOR-
WAY
ELECTRICALLY HEATED MODELS
NO HEAT
MINIMAL HEAT
EXCESSIVE HEAT
STEAM/HOT WATER HEATED UNITS
EXCESSIVE HEAT
MINIMAL HEAT
NO AIR • Power supply line open (no power)
• Fuse blown/circuit breaker tripped
• Motor overload tripped
• Failed switch
• Check power source, check method of control in ON
position
• Replace fuse(s)/reset breaker
• Internally protected motor - should reset automatically
after cool-down, if not, replace motor.
• Replace switch
MOTOR RUNNING/FANS ARE NOT ROTATING
MINIMUM AIR
ELECTRICAL CONTROLS NOT FUNCTIONING WHEN DOOR IS OPEN
TROUBLESHOOTING
SYMPTOMS REMEDY
CAUSE
NO SPEED
ADJUSTMENT
• Speed sensor not detecting
trigger rotation
• Adjust gap between sensor & trigger/
replace sensor
• Broken or damaged flexible hub
• Shaft rotating inside fan
• Selector switch is in off position
• Door limit switch not operating
• Air directional discharge vanes mis-adjusted
• Inadequate intake clearance
• Blower motor operates below speed
• Fan rubbing against housing
• Fan wheels clogged with dirt
• Fan in backwards
• Replace fan sleeve/reengage coupling
• Tighten set screws/tighten fan on shaft
• Turn switch to “ON” position
• Repair or replace limit switch
• Adjust vanes to proper position, see instructions
• Move air curtain or remove obstruction
• Provide adequate space for air curtain
• Improper voltage
• Free fan from housing
• Clean and vacuum fan wheels
• Check fans for blade curve toward discharge
• Thermostat in wrong location - thermostat too
close to discharge
• Improper voltage
• Thermostat not set properly
• Speed sensor not detecting trigger rotation
• Incorrect speed range
• Thermostat in wrong location
• Thermostat not set properly
• Insufficient air over coil
• Improper voltage
• Too high steam/hot water pressure
• Inadequate air flow, fins plugged up, dirty coils
• Insufficient removal of condensation (steam)
• Not enough steam pressure/water temperature too low
• Intake air below design temperature
• Move thermostat away from air stream
• Supply proper voltage
• Change temperature setting
• Adjust gap between sensor & trigger/replace sensor
• Set dip switch to electric heated speed range
• Move the thermostat closer to air stream
• Change temperature setting
• Remove restriction on intake
• Supply proper voltage
• Reduce steam pressure/hot water flow
• Clean intake and coils
• Increase trap size
• Raise pressure for steam/increase water flow
• Increase steam pressure/increase water flow

6
Berner International Corporation
New Castle, PA
724-658-3551
1-800-245-4455
www.berner.com
Berner International warrants all new equipment to be free of defects in workmanship and material for a period of five 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 specified 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 qualified 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 benefit 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.
THEREARENOWARRANTIESWHICHEXTENDBEYONDTHEDESCRIPTIONONTHEFACEHEREOFINCLUDINGTHE
IMPLIEDWARRANTYOFMERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSE.
LIMITATIONOFDAMAGES
Notwithstandinganything to thecontraryabove, customer’sexclusiveremedy for anyandall lossesordamages resulting fromthe
saleofThe Company’sequipmentunderthis agreement,includingbut notlimitedto, anyallegationsof breachofwarranty,breach
ofcontract,negligence orstrict liability, shall be limited,atTheCompany’soption, to eitherthe return ofthepurchase price orthe
replacementoftheparticularequipmentforwhichaclaimismadeandproved. Inno eventshall TheCompany beliable forany
special,consequential, incidental orindirectlossesor damages fromthesale of TheCompany’sequipment under thisagreement.
WARRANTY
Serial Number __________________ Model Number __________________ Date Purchased ____________________________