Biddle MAT 135-E-P User manual

a
Manual
Cold Store Air Curtain
Model MAT
Version 6.0
Original Manual English

COLD STORE AIR CURTAIN
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. . . Contents
1 Introduction 4
1.1 About this manual 4
1.2 How to read this manual 4
1.3 About the unit 6
1.4 Components and accessories 12
1.5 Safety instructions 12
2 Corridor construction 14
2.1 Introduction 14
2.2 Essential components 14
2.3 Possible configurations 15
2.4 Important points 16
3 Installation 18
3.1 Introduction 18
3.2 Safety instructions 18
3.3 Inspection on delivery 18
3.4 Hanging the unit up 19
3.5 Connecting the unit to the water system 24
3.6 Installing control unit 26
3.7 Installing external controls 27
3.8 Connecting the unit to the mains supply 30
3.9 Preparing unit for use 32
4Operation 35
4.1 Introduction 35
4.2 Operation for daily usage 35
4.3 Heating level control 40
4.4 ‘Advanced’ menu settings 42
4.5 ‘Expert’ menu settings 44
5Adjustment 48
5.1 Introduction 48
5.2 General task sequence 48
5.3 Outlet flow rate adjustment 49
5.4 Heating adjustment 49
6 Problem resolution 51
6.1 Introduction 51
6.2 What to do in the event of a problem 51
6.3 Unexpected behaviour 51
6.4 Adverse side effects 53
6.5 Error messages 54
6.6 Error codes 55

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7 Maintenance 58
7.1 Scheduled maintenance 58
8 Service 60
8.1 Safety instructions 60
8.2 Access to air curtain unit interior 60
8.3 Fuses 62
8.4 Disconnecting the RCM module 63
9 Dismantling 64
10 Addresses 65
Keywords 66

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1. . Introduction
1.1 About this manual
This manual explains how to install, maintain and repair the
MAT cold store air curtain.
This document contains important instructions for proper,
safe and effective unit operation.
Please read this manual carefully before working on the unit.
Familiarise yourself with the unit and follow instructions care-
fully.
1.2 How to read this manual
1.2.1 Intended audience
This manual is intended for persons responsible for installing,
operating or maintaining a MAT air curtain.
If you are unfamiliar with MAT air curtains, please read follow-
ing sections in order.
Note:
nAn understanding of the MAT air curtain’s basic
operating principles is essential for correct unit
installation, operation and maintenance.
See also:
1.3.3 "MAT air curtain operation" on page 8

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1.2.2 Designations used in the manual
The following symbols are used in the manual:
Note:
nRefers to an important section in the text.
Caution:
cIf you do not carry out the procedure or action
correctly, you may cause damage to the unit.
Follow the instructions precisely.
Warning:
wIf you do not carry out the procedure or
action correctly, you may cause physical injury
and/or damage.
Follow the instructions precisely.
Danger:
dIs used to designate actions that are not
permitted.
Ignoring this prohibition may lead to serious
damage or to accidents resulting in physical
injury.
1.2.3 Symbols used on the unit and in the manual
The following symbols indicate possible risks or hazards. The
same symbols will also be found on the unit.
SYMBOL DESCRIPTION
wYou have accessed a section of the unit with components carrying a volt-
age.
Access restricted to qualified maintenance staff only.
Caution is required.
wThis surface or component may be hot. Risk of burns on contact.

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1.2.4 Related documentation
In addition to this manual, the following documentation is also
supplied with the unit:
• wiring diagram for installation and servicing.
• a dimensional sketch for purposes of corridor construc-
tion must be provided by the steel supplier (in consulta-
tion).
1.3 About the unit
1.3.1 Application
The MAT cold store air curtain partitions cold store and front
hall climates with the aim of:
• saving energy
• improving temperature control in cold store
• preventing misting and ice formation in cold store without
physically or visually obstructing passageways
MAT air curtains work in combination with regular cold store
doors. The air curtain operates whenever the door is open.
Warning:
wApplications other than those described
above are deemed to be ‘usage other than for
the intended purpose’. Biddle is not liable for
damage or loss resulting from usage other
than for the intended purpose. Usage for the
intended purpose also entails observance of
the instructions in this manual.

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1.3.2 MAT air curtain components
A MAT air curtain is installed around a cold store door. This is
always located in the front hall outside the cold store.
A MAT air curtain consists of various components supplied
with the unit. These have been explained in the figure below.
Note:
nThe MAT air curtain shown in this manual serves
merely as an example. It is feasible that your MAT air
curtain consists of only one air curtain unit. Unit
dimensions may also vary depending on the size of
the cold store door in question. Operation,
however, remains identical unless otherwise stated.
1cold store door
2corridor framework1)
3insulated corridor structure
4protection beam2)
5air curtain unit (master unit: always applied)
6air curtain unit (slave unit: optional or required for wider doorways)
7the master unit has either one or two warning lights (accessory)
8door contact switch controls operating mode (accessory)
9control unit
0control panel
!display
1)The corridor is a special-purpose structural framework. This is not supplied by Biddle.
2)This protection beam is a structural component and is not supplied by Biddle. This item is recommended to prevent
damage caused by collisions with vehicles. The beam may be installed at a later stage to simplify unit installation.

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1.3.3 MAT air curtain operation
General
The air curtain unit creates a constant, vertical airflow across
the full width of the door opening. This acts as a barrier
between indoor climates in the cold store and front hall. This
minimises the exchange of heat and humidity.
Note:
nThe climate partition does not work properly if the
air curtain airflow is disrupted. 1)For this reason:
- all obstructions should be removed from the air cur-
tain’s airflow – even the slightest irregularity can
cause turbulence and disrupt effective operation.
- all air inlets and outlets must be kept clear
- door must be fully open (or closed)
Operating principle for MAT air curtain
MAT operating principle MAT stands for ‘Multi Air stream Technology’. According to this
principle, the MAT air curtain’s airflow pattern comprises
three layers (see figure).
• Airflow ‘A’ enters air inlet from front hall and is expelled
unheated.
• Airflow ‘B’ enters air inlet from cold store and is pre-
heated before being expelled.
• Airflow ‘C’ enters air inlet from cold store and is expelled
unheated.
Airflows are expelled at same flow rate and brought together
at airflow rectifier grille. This avoids turbulence and signifi-
cantly minimises mixing of airflows.
Purpose of heating
Preheating Airflow ‘B’ reduces its relative humidity thus pre-
venting mist formation in the air curtain’s airflow.
The heating level should be set as low as possible to minimise
energy costs. This minimum level depends on ambient condi-
tions in the cold store and front hall. If your MAT air curtain
has been fitted with a humidity sensor (optional), then you can
allow the unit to regulate heating levels automatically.
1) For example, the airflow is disrupted as a person or vehicle passes
through the curtain. Once the person or vehicle has passed, the
airflow re-establishes itself within a few seconds.

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Purpose of corridor
Climate partitioning – door closed The corridor is essential in order for the MAT air curtain to
work properly.
When the cold store door is closed (see figure above), this
acts as a partition between the cold store and front hall.
When the cold store door is open, the MAT air curtain estab-
lishes an effective barrier between these climates (see figure
below). The corridor is required to:
• separate the two indoor climates where the air curtain is
not acting as a barrier
• route air from the cold store into the air curtain unit and
back again without any disruption to the airflow
MAT air curtain climate partitioning – door open
Note:
nEven the slightest opening can prevent the air curtain
from working properly rendering it ineffective. For
this reason:
- corridor must be completely sealed
- corridor must fit seamlessly against air curtain unit
Note:
nWhen the air curtain is running, the corridor’s walls
separate the flow of air originating from the cold
store from the warm and humid air in the front hall.
For this reason:
- corridor must be fully thermally insulated
- thermal bridges should be avoided
Otherwise adverse side effects, e.g. water accumula-
tion and/or ice formation may occur on outer sur-
faces, which can result in unhygienic conditions.

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1.3.4 Type designation
Type designations, when combined, form a unit type code, e.g.:
MAT 135-E-P
MAT 200-EE-S
Different combinations may arise.
Explanation of the type code
1.3.5 Type plate
The type plate is located on the top of the unit.
Example of a type plate Designations on the type plate
T
YPE CODE ELEMENT DESIGNATION MEANING
product series MAT general designation for the series
length 135, 180, 225, 250 discharge length in cm
battery type E electrical heating
EE electrical heating with extra power
H4E hybrid: water heating (element is 4 rows thick) and electrical
heating
sequence P master unit (Primair)
S slave unit (Secundair)
DESIGNATION MEANING
Type complete type code of the unit
Mweightofunit
Pmax For water-heated models:
max. permissible operating pressure
U power supply voltage
Imax max. current
Pmotor max. power consumption by fans
Pheating For electrically heated models:
max. power consumption by heating
element

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1.3.6 Field of application
The cold store air curtain is predominantly used in cold store
front halls. The following operating limits must be observed:
Operating limits for all models
Application limits for hybrid models (type H4E):
Warning:
wThe air curtain may not be used in potentially
explosive atmospheres, wet environments,
outdoors or in very dusty or aggressive air
conditions.
Biddle shall not be held liable for damage
caused by use under these conditions.
1.3.7 CE declaration
The unit is compliant with the applicable CE standards. The
complete CE Declaration of Conformity can be found at:
www.biddle.info
1.3.8 Modifications and changes
Without the approval of Biddle, no changes or modifications
may be made to the unit that could adversely affect safety. The
CE declaration is no longer valid if the unit has been modified
or changed in any way.
Ambient conditions: Temperature 5 °C to 40°C
Max. air humidity 90%, not condensing
Power supply voltage see type plate
Power see type plate
Min. air temperature at inlet in deep-freeze unit -25 °C
Heating medium of water element water containing enough glycol to prevent freezing
Maximum operating pressure see type plate

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1.4 Components and accessories
1.4.1 Components supplied
• suspension frame;
• control unit (with control cable);
• mains power cable (attached to the unit);
•in the event of two units: extension cable (attached to
one of the units);
•only for hybrid models (type H4E): RCM module to
monitor the heat of the water element. (with mains power
cable and control cable);
•Only for hybrid models (type H4E): water-side con-
trol (valve and drive) (The connection cable for the drive is
attached to the unit).
1.4.2 Accessories
• door contact switch.
1.4.3 Components not supplied
• threaded rods (M12);
•othercabling.
1.5 Safety instructions
See also:
8.1 "Safety instructions" on page 60
1.5.1 Safety in use
Warning:
wDo not put any objects into the inlets and
outlets.
Warning:
wDo not obstruct the unit’s inlets or outlets.

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Warning:
wThe upper surface of the unit becomes hot
during operation.
Caution:
cIn exceptional situations, water may run out of the
unit. Therefore, do not place anything under the unit
that could be damaged as a result.
1.5.2 Safety issues relating to installation, mainte-
nance and servicing
Danger:
dThe unit may only be opened by qualified
technical staff.
Warning:
wPerform the following actions before opening
the unit:
1. Switch the unit off using the control panel.
2. Wait until the fans have stopped.
Danger:
dThe fans may continue rotating for a while.
3. Allow the unit to cool down.
Caution:
cThe heat exchanger or, as the case may be, the
heating elements, can get very hot.
4. Disconnect the mains supply ( set the isolation switch to
OFF).
5. If you are going to conduct maintenance or repairs on elec-
trical components: switch the mains supply group off.
6. For water-heated models:
shut off the central heating feed (if possible).
Warning:
wThe fins of the heat exchanger are sharp.

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2. . Corridor construction
2.1 Introduction
This section explains how to install corridor insulation.
It is assumed that by this stage the corridor framework 1has
been installed and is ready for use.
Note:
nThe corridor is a special-purpose structural
framework. This is not supplied by Biddle.
Note:
nThe required corridor dimensions depend on the
situation on site.
See also:
1.3.3 "MAT air curtain operation" on page 8
2.2 Essential components
Essential components include:
• corridor framework 1.
• one or two air curtain unit(s) – for later installation
• two thermally insulated side panels 2that fit seamlessly
around unit(s)
• one fully sealed insulation 3that thermally separates front
hall and deep-freeze unit. This insulation should also sepa-
rate the deep-freeze unit door from the front hall.

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2.3 Possible configurations
The following configurations can be used in a corridor depend-
ing on on-site cold store situation:
THE DOOR ON THE INSIDE OF
THE COLD STORE
(PREFERRED CONFIGURATION)
ANINSULATED DOOR ON THE
OUTSIDE OF THE COLD STORE
(PREFERRED CONFIGURATION)
ANUNINSULATED DOOR ON THE
OUTSIDE OF THE COLD STORE
(DOES NOT HAVE PRIORITY)
The corridor connects directly with
the door opening.
The corridor is built all the way
around door.
In order to gain access to the door
mechanism, sections of the corri-
dor structure need to be removable
or sufficient space needs to be left
between the corridor structure and
the door.
The corridor connects with the
door.
All openings between the open
door and corridor need to be
sealed using flexible material, e.g.
PVC strip.

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2.4 Important points
2.4.1 Essential structural matters
The corridor’s structure is critical in order for the MAT air
curtain to work properly. Pay close attention to the following
points in this section.
Rules regarding shape and dimensions
1. The entire corridor needs to be completely airtight. Even
the slightest hole or gap allowing air to escape will disrupt
proper operation.
2. Side panels must fit seamlessly against the air curtain unit.
3. Side panels must be smooth. Even the slightest protrusion
can disrupt proper operation.
Warning:
wMinimum assembly height should be 1.8 m
measured from unit base.
Caution:
cAdhere strictly to these instructions. Otherwise:
- effective partitioning cannot be achieved and the
MAT air curtain will be rendered ineffective
- side effects may arise, e.g. misting, water accumula-
tion or ice formation, resulting in unhygienic condi-
tions and even potentially hazardous situations.
Rules regarding materials
1. Corridor must be fully thermally insulated.
2. Thermal bridges should be avoided.
Caution:
cDo not leave any components uninsulated,
otherwise, water may accumulate or ice may form
on outer surfaces, which can result in unhygienic
conditions.

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2.4.2 Important points
Note:
nPay particular attention to the following points when
assembling the corridor:
- Mount side panels 1to inside of framework (see fig-
ure), not to outside of framework.
- Seal gaps between insulation sections.
-Sealspace2above door opening, between wall and
unit.
- Do not obstruct area around air inlet 3at rear of
unit – air inlet must be positioned entirely within
corridor.
- When using pliable materials for sealing gaps 4
around door, do not forget to seal opening 5
around door guide rail.
- Unit housing 6has been thermally insulated. If unit
is fitted seamlessly into corridor, then it is not neces-
sary to use additional insulation material.
-Leavespace7clear above unit for access when per-
forming maintenance.

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3. . Installation
3.1 Introduction
This section explains how to attach and connect MAT air cur-
tain components and prepare it for use.
It is assumed that by this stage the corridor is ready for use.
A lifting vehicle is needed to install air curtain, e.g. a lifting plat-
form or forklift truck.
3.2 Safety instructions
Warning:
wInstallation activities may only be performed
by technical staff qualified for this purpose.
Warning:
wBefore starting installation: read the safety
instructions.
3.3 Inspection on delivery
• Check the unit and the packaging to ensure they have been
delivered in good order. Notify the driver and the supplier
immediately if any shipping damage is detected.
• Ensure that all components are present. Notify supplier of
any missing parts immediately.

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3.4 Hanging the unit up
3.4.1 Two units
If two air curtain units have been installed, then the master
unit may be placed on either the left- or the right-hand side.
Take position of control unit into account.
Follow instructions below for both units.
See also:
3.6 "Installing control unit" on page 26
3.4.2 Preparation
1. Remove packaging material from unit, but leave unit on pal-
let.
2. Screw a threaded rod 1into all four screw holes 2on
top of unit to a depth of approx. 3 cm.
3. Lock each threaded rod using a lock nut 3. Tighten nuts
well.
Warning:
wThreaded rods must be securely locked.

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If pallet is too wide
If pallet does not fit between corridor walls, then swap out
pallet for a smaller one:
1. Position suspension frame 4above threaded rods.
2. Attach suspension frame to each threaded rod using nuts
5.
3. Raise unit on suspension frame using a forklift truck.
4. Swap out pallets.
5. Lower unit onto pallet.
6. Dismantle suspension frame.