flakt woods RoomMaster ABR-2 Installation guide

RoomMaster ABR-2
Operation and maintenance

Fläkt Woods 8060 GB 2009.05 3 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
Important safety information
Read carefully through the directions, advice and warning texts contained in the operating instruc-
tions before the room unit is installed and taken into service.
The RoomMaster size 2 will then function in a satisfactory fashion and provide the greatest benefit.
✧The unit must be operated by adults. Do not allow children to play with it or touch the controls.
✧All installation work and interventions in the product must be performed by an authorized spe-
cialist. Work done by inadequately qualified persons may impair the function of the RoomMas-
ter and cause damage to individuals and property.
✧Servicing and repairs should be carried out by a service company approved by the supplier. Use
only spare parts obtained from them.
✧Make certain that the power supply cable is not trapped when installing or moving the unit.
✧The unit is heavy. The risk of crushing injury is present when lifting or disassembling the unit.
If necessary, use appropriate lifting accessories or other suitable equipment. Take care when
moving the unit.
✧Use protection gloves when maintenance and repairs are performed.
Safety information

Fläkt Woods 8060 GB 2009.05 4 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
For the user
RoomMaster system .............................................................................................5
Function..................................................................................................................5
Control panel .........................................................................................................6
Operating mode keys - Function ........................................................................6
Alarm ......................................................................................................................6
Supply air temperature ........................................................................................6
Settings via operating mode keys.......................................................................6
Locking operating mode keys.............................................................................6
For service personnel
Component parts...................................................................................................7
Safety notice...........................................................................................................7
Maintenance interval............................................................................................7
Opening the unit ...................................................................................................7
Filter ........................................................................................................................8
Filter replacement interval...................................................................................8
Replacement of filter cassette ..............................................................................8
Replacement filter .................................................................................................8
Rotary heat exchanger..........................................................................................8
Rotor sealing strip.................................................................................................8
Replacement of rotor drive belt ..........................................................................8
Electrical coil..........................................................................................................9
Overheating protection for electrical coil ..........................................................9
Cleaning of fans.....................................................................................................9
Dismantling and re-assembly of fan unit ..........................................................9
Replacement of bearings and fan impeller wheel............................................9
Ducts and combi-cover.........................................................................................9
Supply air terminal device...................................................................................9
Cleaning of sound attenuator..............................................................................9
Replacement of terminal device insert.............................................................10
Replacement of diffuser mat behind front grille ............................................10
The diffuser mat is replaced as follows ...........................................................10
Air cooler, water ..................................................................................................10
Venting of air cooler............................................................................................10
List of contents

Fläkt Woods 8060 GB 2009.05 5 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
RoomMaster system
The RoomMaster system consists of a unit positioned
in the room with a supply air and exhaust air capability
and with an integral low-impulse terminal device. The
purpose of this ventilation system is to provide good
ventilation of the premises in return for the least possible
intervention.
Function
The outdoor air is filtered, and a very considerable pro-
portion of any heat in the exhaust air is transferred to the
supply air via a rotary heat exchanger. The air is supplied
to the premises via a displacement supply air terminal
device, which allows the air to “flow“ out slowly over the
floor and to displace any heat and impurities towards the
ceiling, from where they are led away as exhaust air.
After starting-up, the unit functions automatically.
The front of the unit has a control panel with a text
display window, push-buttons and a warning lamp for
fault indication.
Fig. 1. RoomMaster system
Function
Supply air
Outdoor air
Extract air
Combi-hood
Exhaust air
Motorized damper
Cooling water
c = 2

Fläkt Woods 8060 GB 2009.05 6 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
Control panel
The control panel has an illuminated text display win-
dow and a keyboard, as well as a warning lamp for fault
indication.
The four operating mode keys at the top are used to
select the desired operating mode.
The five lower setting keys are used to set the air flow
and temperature, etc., during commissioning/installa-
tion.
The text display window shows the operating status,
air flow, temperature and other setting values in clear
text.
In the event of a fault function occurring, the red
warning lamp begins to flash and an alarm message is
shown in the text display window.
Alarm
The red warning lamp on the control panel flashes in the
event of an alarm. The fault is corrected by the supervi-
sory staff according to the alarm message in the text dis-
play window. Press the AUTO operating mode key twice
to restart the unit, which then automatically performs a
self-test. The warning lamp is extinguished once the fault
has been corrected.
See also the instructions, “Installation - Commission-
ing“.
Supply air temperature
The supply air temperature is set to 19º C on delivery,
which is the recommended value to achieve good ventila-
tion and avoid draughts in the immediate vicinity.
Settings via operating mode keys
The settings are made when the unit is installed. The set
values may only be changed by trained personnel.
See also the instructions, “Installation - Commission-
ing“.
Locking operating mode keys
Each of the “Overtime operation“, “Ventilation“ and
“Stop“ functions can be blocked via the setting keys on
units manufactured on or after 01.01.96.
Operating mode keys - Function
Automatic mode: the unit is controlled accord-
ing to the selected setting.
Overtime operation: a timer function which
provides normal operation for 3 hours
Ventilation: produces maximum flow for 15
minutes with a desired value of 15º C for the
supply air temperature.
Stop: the unit stops: should only be used when
there is a temporary need to shut down the
ventilation.
Fig. 2.
AUTO
STOP
Function
Window
Alarm
Operating
mode keys (4)
Setting
keys (5)

Fläkt Woods 8060 GB 2009.05 7 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
Control card
Limit switch
Supply air filter
Exhaust air fan
Rotary heat exchanger
Exhaust air filter
Electric heater
Supply air fan
Supply air
terminal device
Cooling coil
(part code c=2)
Fig. 3. Component parts
Safety notice
Always switch off the power supply prior to inspection
and service.
All settings are always stored in the control unit, includ-
ing after power supply failure.
Opening the unit
The inspection covers have two key-operated locks.
Opening the covers causes the power supply to the unit
to be cut off by the limit switch.
Maintenance interval
It is recommended that the following maintenance in-
terval is adhered to in order to prevent faults in the unit
and to ensure a good function in other respects.
Component Interval Remedy
Filter 6 months Replace as required
Fan 12 months Clean as required
Heat exchanger 12 months Clean as required
Supply air
terminal device 12 months Clean as required
Maintenance

Fläkt Woods 8060 GB 2009.05 8 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
Fig. 5.
Filter
The unit is equipped with supply air and exhaust air
filters to ensure clean supply air and to protect the com-
ponent parts.
As dust is gradually separated in the filter, the pres-
sure drop falls and the control unit attempts to maintain
the set air flow. If the pre-set maximum increase in the
pressure drop is achieved, an alarm is given and the red
lamp flashes.
Filter replacement interval
The recommended interval is 6 months, although this
is determined by experience. This is because large local
variations in air purity occur due to the type of dust, the
dust content and the number of particles.
Replacement of filter cassette
1. Open the inspection covers, release the retaining de-
vices (red) and withdraw the filter cassette.
2. Push the new filter cassette into the guide and tension
the retaining devices.
3. Check for damage to the sealing gaskets on the filter
cassette and the inspection covers.
4. Close the covers.
If the replacement was initiated by a filter alarm, the unit
will automatically perform a self-test and will reset the
alarm when the covers are closed.
Both filters must be replaced in the event of a filter
alarm.
Replacement filter
Supply air and exhaust air filter. Filter Class F7 (F85).
Order Code ABRZ-08-2-07.
Figur 4.
Rotary heat exchanger
Fig. 6. Adjusting belt length to give required belt
tension.
Maintenance
The rotary heat exchanger is very important for the func-
tion and economy of the unit. It is important, therefore, to
keep it clean and in good condition.
The rotor is normally self-cleaning, because the air
flow direction is constantly changing.
The surfaces of the rotor can be vacuum cleaned, if
necessary, using a soft brush nozzle.
The cleaning sector prevents the exhaust air from be-
ing transferred in the supply air during rotation.
The axial bearings of the rotor are lubricated for life,
and no subsequent lubrication is necessary.
Rotor sealing strip
The rotary heat exchanger in ABR is provided with a
sealing strip to reduce the leakage between the supply air
and exhaust air ducts. Check that the strip makes contact
with the sheet metal casing for its entire length, and ad-
just if necessary.
Replacement of rotor drive belt
1. Tape the new drive belt to the rotor and rotate it so
that the end becomes visible.
2. Press the supplied pin in the ends of the drive belt.
3. Check that necessary belt tension is obtained. Adjust
the belt length when necessary.

Fläkt Woods 8060 GB 2009.05 9 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
Fig. 7.
Fig. 8.
Overheating protection for electrical coil
The coil is equipped with two temperature limiters: one
with automatic resetting, set to 40º C, and an overheating
protector with manual resetting, which trips at 120º C.
Resetting is performed with two buttons on the over-
heating protector positioned on the rear of the dividing
wall on which the coil is located (where the exhaust air
filter is located).
Cleaning of fans
The fans for the ABR room unit are directly driven. Both
fans should be checked and cleaned as required. Wipe the
fan with a cloth. Clean the fan impeller using a vacuum
cleaner fitted with a soft brush nozzle. Take care to clean
all the fan blades, to prevent imbalance arising in the fan.
Dismantling and re-assembly of fan unit
1. Separate the connector for the fan. Note the lock.
2. Remove the electrical heater, if present (applies to
supply air fan).
3. Remove the front two bolts, and lift out the fan unit.
Check the vibration damping when refitting.
Electrical coil
The electrical coil should be checked and cleaned as re-
quired, since an accumulation of dust can cause odours
and, in the worst case, fire.
If the need arises, the dividing wall complete with the
electrical coil can be pulled out. Allow the coil to cool be-
fore pulling it out and cleaninging it. First disconnect the
connector. Note the lock.
Fig.9.
Replacement of bearings and fan impeller
wheel
The bearings in the fan motor are lubricated at the factory
and maintenance-free.
The entire fan unit must be replaced in the event of
damage. This ensures that high quality, with a balanced
unit, is achieved for the fans.
Ducts and combi-hood
The front panel is detachable to allow the connected
ducts to be checked; these should be cleaned, if necessary.
If any other type of supply air and extract air terminal
device is used, the maintenance should be adapted to the
design in question.
Maintenance
Supply air terminal device
The front grille consists of two halves, each of which are
detachable in order to permit the supply air device and
the sound attenuator to be checked and, if necessary,
cleaned.
Vaccum both sides of the supply air device once a
year.
Cleaning of sound attenuator
1. Open the inspection covers, and remove the two bolts
located on the top edge of the front grille.
2. Undo the four bolts (using a 13 mm spanner) located
on the bottom edge of the front grille by approx. two
turns, and pull out and lift off the front grille.
3. If the unit has a cooling coil, fold it forwards; the coil
has flexible hoses for the water connection.
4. Undo the bolts along the edge of the central plate, and
lift out the central plate with the dividing bag.
5. Lift out the terminal device insert.
N.B. On re-assembly, the terminal device insert must be
secured laterally in a groove on the fan outlet on the rear
edge of the terminal device.

Fläkt Woods 8060 GB 2009.05 10 Specifications are subject to alteration without further notice.
RoomMaster ABR-2 OPERATION AND MAINTENANCE
Fig. 11.
Fig.10.
Venting of air cooler
The bleed valve is located on the right-hand side of the
air cooler connection pipe.
Venting takes place with the circulation pump
switched off. The pump is started and stopped a few
times interspersed with venting. The bleed valve must be
closed when the pump is running.
Connector
for control
valve
Condensation
water pipe
Cooling water pipe
Cooling coil
Bleed valve
Temperature
sensor,
supply air
Replacement of terminal device insert
The cone-shaped terminal device insert, known as the
“bag“, which is made of polyurethane foam, does not
normally require to be replaced. It is very open with large
pores, which prevents blocking. In the unfortunate event
of its becoming blocked, replacement may be necessary.
The terminal device insert is replaced as follows:
1. Remove the front grille according to the above instruc-
tions.
2. Cut the strap around the terminal device insert. Re-
move the terminal device insert.
3. When fitting a new terminal device insert, first turn it
inside out.
4. Push the terminal device insert onto the sleeve and
tighten the new strap.
5. Replace the front grille.
Replacement of diffuser mat behind front
grille
The diffuser mat, which is made of polyurethane foam,
should not normally require to be replaced, because it is
very open (like the terminal device insert). It may eventu-
ally become damaged by “external effects“, however.
The diffuser mat is replaced as follows
1. Remove the front grille according to the above instruc-
tions.
2. Pull out the mat, which is glued to the front grille at a
number of points. Scrape off any remains.
3. Cut off pieces of the self-adhesive velcro tape, and
glue them in position next to the old adhesive points.
4. Insert the mat, and press down slightly harder over
the velcro tapes.
5. Replace the front grille.
Air cooler, water
In order to achieve the desired cooling effect, the air
cooler must be clean and well ventilated. In conjunction
with normal filter replacement in the unit, cleaning is
only required after a few years‘ operation. The fins of the
cooling coil are cleaned with a soft brush, compressed air
or a vacuum cleaner. See “Cleaning of sound attenuator“
for details of how to open the terminal device grille.
Maintenance
Unit covers
Sound attenuator baffle
Holder
Terminal
device insert
Strap
Bolts
Central plate
Front grille with
diffuser mat
Front grille with
diffuser mat
Damper for axtra
supply air teminal
device (accessory)

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