Remak DoorMaster P Series User manual

Air Curtains
25AHEAI
Catalogue, Operating and Installation Instructions

2
Air Curtains
Table of Contents
Basic information ................................................................... 3
Introduction .................................................................................................................... 3
Operating Conditions and Arrangement ......................................................................... 4
Design Description ........................................................................................................ 4
Energy Savings .............................................................................................................. 4
Installation ...................................................................................................................... 4
Marking........................................................................................................................... 4
Technical Parameters............................................................. 5
ew Air Curtain Planning........................................................ 6
Air Curtain Designing Nomogram ..................................................................................
Designing Nomogram Glossary ..................................................................................... 7
Water Discharge ............................................................................................................ 7
Air Curtain Control and Regulation ................................................................................. 7
VCP Control Unit ..................................................................... 8
Connection Examples ............................................................ 9
Installation, Operation and Service ..................................... 12
Wiring and Safety ......................................................................................................... 12
Commissioning ............................................................................................................ 12
Wiring and Safety ......................................................................................................... 12
Operation, Maintenance and Service ........................................................................... 13
Operational Inspections ............................................................................................... 13
Packaging, Spare Parts and Disposal ................................ 14
Type Plate .................................................................................................................... 14
Information and Safety Labels ...................................................................................... 14
Storage ........................................................................................................................ 14
Packaging .................................................................................................................... 14
Disposal ....................................................................................................................... 14
Waste Specification ..................................................................................................... 14

4
Air Curtains
Figure 2 - Type marking
Operating conditions
Air curtains are designed for indoor installations (environ-
ment: normal, basic) above or next to the door (possibili-
ties of their arrangements are shown in the figure above).
They are suitable for all kinds of buildings where busier
traffic of freight and manipulating means or persons going
in and out of the building can be expected. Typical instal-
lation sites are production and industrial buildings, sto-
res and transport terminals, gates for trucks, car servi-
ces, garages, car washes, fairgrounds, markets, drying
houses, etc. It is advisable to consult the suitability of a
given type of air curtain for a particular environment with
the manufacturer or the air-handling device designer.
Construction Description
Air curtains are produced in four output rating lines, and
the length of the exit slit is designed for the given door.
As standard, the air curtain and its parts are made of
galvanized sheets (Zn 275 g/m2) without colour coating
finish. Optionally, the air curtain can be delivered finished
with RAL 9002 (or other) baked enamel. The exit slit is
fitted with directing fins.
DoorMaster P air curtains are equipped with a duct radial
fan directly driven by the motor, a VMR inlet screen and
an STB exit slit. The assembly of the air curtain can also
be optionally equipped with an EU3 insert filter. The filter
insert can be partially regenerated. Full regeneration of
the filter insert can only be performed by replacing the
filtrating textile. The air can be heated either by the Cu/Al
finned water heater or electric heater.
Energy savings
The high-pressure DoorMaster air curtains of the "P" se-
ries, developed by REMAK, provide more economical ope-
ration at a significantly lower price compared to competiti-
ve low-pressure air curtains. Operating costs, created espe-
cially by the air heating costs, are less than half compared
to so-called "economy" or "energetically active" air curta-
ins. This extraordinary economical operation of DoorMas-
ter air curtains is based on their high-pressure concept.
These air curtains feature a narrow exit slit which, in spite
of having high pressure loss (hundreds of Pa) and which
need the use of relatively high pressure fans due to high air
flow velocity of 10 to 18 m/s, provide long reach of the air
stream while minimizing air flow rates.
Common air curtains must be equipped with a 4 to 5 times
wider exit slit (approx. 1 0 mm) compared to high-pressu-
re air curtains. They work at a slightly lower air velocity but
require 4 times higher air flow rates. The following table
illustrates the above-mentioned relation comparing the he-
ating inputs of common, economy and high-pressure air
curtains per 1 m height of the air curtain stream.
* The so-called economy air curtain is sometimes identified as an
active one. Heating power input is calculated for ∆t = 20°C.
P - 7 W - 300
unit slot length in cm
200, 250, 300, 350, 400
air heating type
W ... water
E .... electric
N .... no heating (low temperature)
air curtain size (output)
, 7, 8, 9
air curtain type (P - industrial)
Installation
Before installation, familiarize yourself with the Sa-
fety Rules on page 12.
The air curtain is delivered disassembled. Individual ele-
ments of the air curtain can be connected together by me-
ans of bar flanges while keeping their prescribed order. Self-
adhesive sealing must be applied between the flanges. The
conductive interconnection of all air curtain parts must be
ensured by the fan-shaped washers. The air curtain must
be anchored to the wall or building structure so that its
stability will be ensured. As standard, the air curtain is not
fitted with any fixing elements.
Type identification
The following picture describes type identification for accu-
rate specification of DoorMaster P industrial air curtain units.
Tabulka 7  popis
Basic Information
Table 1  Energy savings
Slot Speed Input Ratio
mm m/s m3/s m3/h kW %
Regular 1 0 10 1, 57 0 39 100
Economic* 1 0 10 1, 57 0 19 50
Hi-pressure 35 12 0,42 1512 10 2
Airflow rate
Unit type
Figure 1 - Options of arrangement

5
Air Curtains
Technical Parameters
(W)
(E)
(N)
* limited air heating efficiency
No Heating
DoorMaster
type
P-6N–… P-7N–… P-8N–… P-9N–…
Air stream reach range
m
Max. air flow rate
m
3
/h
4000 6000 6200 8400
Max. air flow rate.
m
3
/s
1,11 1,67 1,72 2,33
Power supply
Max. total el. current A 4,1 6 5,1 6,8
Max. total input kW 2,5 3,5 2,8 3,8
Protection degree
Filtration class
Width A m 0,6 0,7 0,8 0,9
Depth B m 0,35 0,4 0,5 0,5
Exit slit length L1 m
Installation heightL2 m 1,32 1,43 1,59 1,69
Mean weight m kg 81 110128157
G3
2,0 to 4,0
2,0 to 4,0
3 x 400 V / 50 Hz
IP 54
Electric Heating
DoorMaster
type
P-6E–… P-7E–… P-8E–… P-9E–…
Air stream reach rangem
Max. air flow rate
m
3
/h
3950 5950 6150 8350
Max. air flow rate.
m
3
/s
1,10 1,65 1,71 2,32
Power supply
Max. fan el. current A 4,1 6,0 5,1 6,8
Heating el. current A34,1 45,5 45,5 45,5
Max. fan inputkW 2,5 3,5 2,8 3,8
Max. heating input kW 22,5 30* 30*30*
Protection degree
Filtration class
Width A m 0,6 0,7 0,8 0,9
Depth B m 0,35 0,4 0,5 0,5
Exit slit length L1 m
Installation heightL2 m 1,92 2,18 2,34 2,44
Weightm kg 116 156 180 210
G3
2,0 to 4,0
2,0 to 4,0
3 x 400 V / 50 Hz
Fan IP 54, Heater IP 20
Water Heating
DoorMaster
type
P-6W–… P-7W–… P-8W–… P-9W–…
Air stream reach rangem
Max. air flow rate
m
3
/h
3900 5900 6100 8300
Max. air flow rate.
m
3
/s
1,08 1,64 1,69 2,31
Power supply
Max. total el. current A 4,1 6 5,1 6,8
Max. total input kW 2,5 3,5 2,8 3,8
Protection degree
Heating medium
Heat exchanger connection
Filtration class
Width A m 0,6 0,7 0,8 0,9
Depth B m 0,35 0,4 0,5 0,5
Exit slit length L1 m
Installation heightL2 m 1,47 1,58 1,74 1,84
Weightm kg 100 125 159 190
male thread G 1"
G3
2,0 to 4,0
2,0 to 4,0
3 x 400 V / 50 Hz
IP 54
water up to 110°C and 1.5 Mpa
The following tables include important technical parameters of the
produced air curtains arranged according to the type of air heating, i.e.
water (W), electric (E) or without heating - a low temperature version
(N).
The exit slit height can be ordered from 2 to 4 m. The reach range of the
air stream changes depending on the selected exit slit height. The
dimensioning of the exit slit can be done using a nomogram (page 6).
L1
L2
BA
L1
L2
airintake
fan
discharge slots
insert filter
BA
air intake
fan
discharge slots
insert filter
water heater
L1
L2
BA
air intake
fan
discharge slots
insert filter
electric heater

6
Air Curtains
Projecting procedure - detailed explanation of terms and projecting procedure is on page 7
- select type of heating (for instance water - W)
- select orientation and location of air curtain according to pic. 1 on page 4 (e.g. one-side unit on a side)
- select air curtain range (for instance 2,7 m which corresponds with gate width for the selected orientation)
- select operating conditions  (for instance regular)
- draw a vertical line from point  on the curve, which determines the discharge airflow velocity (for instance 11, m/s)
- select discharge slot length  (for instance 3 m, which corresponds to gate height for the selected orientation)
- draw a vertical line up from point  on the curve, which determines the minimum airflow rate needed (for instance 4.200 m3/s)
- draw a horizontal line from point  on the curve, which determines the slot pressure drop (for instance 125 Pa)
- point of intersection of the lines in point  lies with some of the coloured fields (for instance in the green field)
- the coloured field, in which point  is located, determines the proper air curtain unit size (e.g.green colour > P-8W-300)
- parabolic prolongation to full curve demarcating the coloured field from the upper side will determine the real working point  of the air curtain
- the real (higher than the minimum needed) airflow (for instance 5.000 m3/s) corresponds to the real working point 
- the necessary heating output  (for instance 35 kW) corresponds to the real airflow
- the necessary water flow rate  (for instance 0,42 l/s) corresponds to the heating output needed - applicable for water heated curtains and water
drop of 90/70°C.
- the adequate water pressure drop  (for instance 3,7 kPa) to the necessary water flow of the selected curtain (P-8...)
Air velocity in slot (m) Volume of air (m3/h)
slot length 4 m
slot length 3 m
slot length 2 m
Air curtain range (m)
water pressure
loss (kPa)
water
volume (l/s)
heated output
needed (kW)
Air Curtain Designing omogram

7
Air Curtains
The nomogram and procedure for air curtain design is on
page . On your request, the manufacturer will perform
complete planning of the air curtain assembly. The input
data and request form are on page 15.
Designing omogram Glossary
Type of Air Heating
It is necessary to determine the type of air heating in ac-
cordance with the installation conditions. Water heating
(W) is the most convenient type of heating. If hot water is
not available, then electric heating (E) can be used. If air
heating is undesirable, then air curtains without heating
(N) can be used; however, the efficiency of such air curtain
is limited.
Orientation and Arrangement of the Air Curtain
The air curtain orientation must be selected in accordance
with the door type. The air curtains for a section door are
always installed on the door's sides. The air curtains for a
wing door are always installed above the door. The single-
sided air curtain arrangement will mostly do for door areas
up to 10 m2. The double sided air curtain arrangement should
always be selected for door areas above 12 m2, or if large
objects (truck, palettes of goods, etc.) are required to be
situated within the door area for a longer time. Another re-
ason for using the double sided arrangement can be the
need to divide the larger ground area of the single side air
curtain into two smaller ones.
Air Flow Velocity in the Exit Slit
The air flow velocity in the exit slit depends on the required
reach range of the air curtain and the selected working
conditions. This parameter is only informative for the de-
sign procedure.
Air Flow Rate (Quantity)
First, the "minimum needed" air flow rate (point ) is deter-
mined using the designing nomogram. This air flow rate is
given by the minimum outlet air flow velocity and the exit
slit area. However, the actual air flow rate corresponding to
the air curtain fan (point ) will be significantly higher, and it
will lie on the intersection of the parabola going through
point , and the solid curve enclosing the upper side of the
respective coloured field.
ecessary Heating Output
The necessary heating output is derived from the actual
airflow rate at ∆t = 20°C. The output of electric heaters can
be 22 kW or 30 kW while controlled by the control unit.
The output of the water heater is given by the heating water
quantity (discharge); its discharge must be ensured by the
pump. This parameter is irrelevant for the low temperature
air curtain (without heating).
Water Discharge
The heating water discharge is an important parameter for
the water-heated air curtains; the heating water discharge
is constant during the air curtain operation. In most cases,
there is no need for further control of the heater output than
just switching the pump on and off. The nomogram has
been created for a temperature gradient of 90/70°C. If the
air curtain processes only circulating air and the room tem-
perature does not drop below +5°C, antifreeze protection
will not be necessary.
This parameter is irrelevant for low temperature (N) and
electric (E) air curtains.
Heating Water Pressure Loss
The heating water pressure loss for the respective water
heater and heating water discharge is included in the no-
mogram. The total pump delivery head is calculated by
adding the piping pressure loss to the heater pressure loss.
This parameter is irrelevant for low temperature (N) and
electric (E) air curtains.
ew Air Curtain Planning
Table 2 - orientation and arrangement
Table 3 - Air control
Reach Range and Length of the air curtain
The reach range is the perpendicular distance from the exit
slit where the air flow velocity is still at the minimum limit.
The reach range and the air curtain length depend on its
orientation and arrangement. The nomogram has been de-
veloped for standard working conditions.
Standard Working Conditions
nPremises with one door (separation of two indoor areas)
nConstant-pressure air handling within the premises.
nWithout ram wind
nIntermittent and momentary door opening
nBuilding without "chimney effect"
on-standard Working Conditions
nOver or under pressure within the premises
nSeveral doors (especially if they are situated
on opposite sides)
nFrequently opened door
nDoor open for longer times
These factors shift the nomogram selection curve to the
right (point).
Air Curtain Control and Regulation
VPC control units (resp. STD relays) can be used to con-
trol, regulate, supply and protect the air curtains. The type
of prescribed controller according to the used heating sys-
tem is included in the following table.
DoorMaster "P" air curtains may only be connected to prescri-
bed controller types. Other ways of protection (control) are not
allowed concerning the warranty conditions. For wiring dia-
grams of the A, B and C controllers, refer to pages 9 to 11. For
a description of controllers, see page 8.
Air heating control unit Connection
no heating (N) STD A
water (W) VCP-W B
electric (E) VCP-E C
Range Slot length
side gate width gate height
overhead gate height gate width
side 1/2 gate width gate height
overhead gate height 1/2 gate width
Arrangement
one-side
two-side

8
Air Curtains
VCP control units
Operating conditions, position and location
VCP-series control units are designed for interior use in
dust-free and dry environments without chemicals. They
are designed according to recommendation of IEC 33
2000-3, enclosure NM, table 32-NM1 for regular effect
classes. At the same time they meet the requirements
of Czech standard ÈSN 33 0300, article 3.1.1 - basic
environment. Protection class of plastic box is IP 54 in
case of closed door and IP 40 in case of opened door.
The control units can be mounted directly on surfaces of
combustible class of A and B according to of Czech stan-
dard ÈSN 73 0823. Permissible ambient temperature
is from +5 to 40°C. The units are fixed in vertical position
either directly on the wall or they are flushmounted 50
mm under the plaster. The cables can be led through
plastic troughs or under the plaster. The unit has to be
positioned taking into consideration easy access of oper-
ators and cable connections.
In case of VCP-E units it is necessary to secure suffici-
ent prote-ction of the lead-in wires so that the residual
over-voltage level would not exceed 1,2 kV.
Construction and materials
All types of VCP control units are built into plastic boxes
with transparent front door behind which the control ele-
ments are located. The outer dimensions of the plastic
box are 275 x 370 x 140 mm. The power section consi-
sts of input terminal board for connection of supply cable,
circuit breakers, contactors and of terminal boards for
connection of the particular elements of the air curtain
unit. Plastics, copper, aluminium and zinc-coated metal
sheets are used in the inner construction. Components
inside the unit are fitted on DIN strips or on printed con-
nection boards.
Control and protection
Fan protection against overheating is secured by fitting
the fan coils with thermocontacts that will disconnect
the protective circuit when the marginal temperature is
exceeded. It will make the control unit disconnect the fan
lead-in wires from power supply. After the coils are coo-
led down and the thermocontacts are switched on, the
air curtain unit fan will not be auto-matically switched on.
The unit can be started by operator after finding out the
cause and repairing the defect. Easy and simple control
is an advantage of VCP control units.
Start and stop
The gate air curtain unit is started and stopped by a
switch on the front panel of control unit marked START
- AUTO. Permanent operation of the unit in manual
mode can be adjusted by switching the switch over
to the START position and the unit operation is indi-
cated by switch control light. Switching the
switch over to AUTO position, the mode of automatic
operation switching by 250V / 0,5 A external poten-
tial-free contact will be set. This contact is to be con-
nected to the control unit terminals. If the contact is
not connected, the unit is switched off in
AUTO position. Electric heated air curtain units have
the safety run-out of the fans secured until the mo-
ment the temperature in electric heater chamber drops.
Definitive air curtain unit stop (for instance seasonal)
is made by switching the main switch off.
By HEATER DISCO ECTI G SWITCH (VCP-E) is it possi-
ble to disconnect manually the electric heater control.
The red control light on this switch indicates switching
the heater on. Temperature of discharge air of the air
curtain unit is set by thermostat upon putting the unit into
operation. By PUMP DISCO ECTI G (VCP-W) we can
disconnect the hot water pump switching, which is other-
wise switched on simultaneously with unit starting. If a
defect occurs on fan or electric heater in operation of the
gate air curtain unit, the control unit will stop unit auto-
matically. After removing the defect, it is necessary to
reactivate the circuit breakers.Then the unit can be re-
started.
VCP Control Unit
Fan circuit
breaker
Heating circuit
breaker
VCPE VCPW
370
275
Fan circuit
breaker
Pump disconnecting switch
Start - Auto
Main switch
(circuit breaker of supporting circuits)
Main switch
(circuit breaker of supporting circuits)
Heater disconnecting switch
Start - Auto

9
Air Curtains
3x 400V + N + PE
(CYKY 4B x 1,5)
3x 400 V + PE (CYKY 4B x 1,5)
STD 25
main power supply
230V AC (CYSY 2A x 1)
A
Connection of low temperature unit
without heating ( )
Figure 3 shows the connection of the low temperature air
curtain (i.e. without air heating). Protective STD relay ensu-
res the start and stop of the air curtain and overloading pro-
tection of the fan motor. The protective relay will automatically
switch the fan motor off if the maximum permissible motor
winding temperature of 130°C is exceeded. The protective
relay is equipped with a restart button (RESET). The air cur-
tain can be manually controlled by the switch situated on the
STD relay. If switching of the air curtain by an external contact
connected to the door opening mechanism is required, the
contactor must be inserted in front of the protective relay (if
the power supply fails, the fan will be automatically switched
on by the circuit breaker after the power supply is resumed).
The STD relay is designed for indoor and outdoor use in a
chemical-free and non-explosive environment. Degree of
protection is IP54. Maximum permissible ambient tempera-
ture ranges from -25°C to +40°C. The protective relay is enc-
losed in a plastic casing which can be mounted directly on a
wall, or partly embedded into plaster. The protective relay
can also be installed without the plastic casing on the DIN
bar inside the control unit.
Observe the rules on page 12.
Connection Examples
Figure 4
Figure 3
3-phase fan motor
STD 25 protective relay
M
1L1
L2 L3
PE
3 5
4 2 6
TK
TK
TK TK
V1
U1
W1
PE
STD 25 protective relay
Nominal voltage U 3x 400V, 50 Hz
Minimum voltage Umin 0 V
Maximum voltage Umax 400 V
Minimum current Imin 0,45 A
Maximum current Imax 25 A
Dimensions WxHxD 78 x 140 x 93
Weight m 0, kg
STD 25 technical parameters

10
Air Curtains
B
Connection of water heated unit (W)
3 x 400 V + N + PE
3 x 400 V + PE
VCP-W
230V AC
Figure 5 shows the connection of the water-heated air
curtain to the VCP-W control unit. The control unit ensu-
res start and stop of the air curtain and overloading
protection of the fan motor. Further, it provides pump
protection. The switching of the pump is related to the
air curtain operation. During the summer season, the
pump can be taken out of operation by switching the
pump trip switch off. The water heating system is not
equipped with antifreeze protection and therefore it may
only be installed in non-freezing areas where the tem-
perature does not fall below +5°C. The air curtain can
be controlled either by the switch situated on the front
panel of the control unit or by an external contact con-
nected to the door opening mechanism; then the air
curtain is automatically started/stopped in relation to
the door opening/closing. For control of simple applica-
tions, an STD relay can be used which simultaneously
ensures overload protection of the fan motor. In such
case, the pump supply and protection must be ensured
separately. The water-heated air curtains have no outlet
air temperature control.
Observe the rules on page 12.
230V AC 230V AC
èerpadlo
door contact
main power supply
Connection Examples
Figure 5
Figure 6
Heating water
circulating pump
VCP-W control unit
3-phase fan motor
Main supply line
External starting
PE
4B x 1,5