AIR HEATING UNIT HEATMASTER ACJB INSTALLATION, OPERATION, MAINTENANCE AND SPARE PARTS

AIR HEATING UNIT HEATMASTER ACJB INSTALLATION, OPERATION, MAINTENANCE AND SPARE PARTS

2 Air Heating unit ACJB - Technical manual CONTENTS OPERATION AND MAINTENANCE (FOR USER) System, functions, main components...3 Control panel, operation... 4 Maintenance, filter replacement...5 INSTALLATION (FOR INSTALLER AND SERVICE PERSONNEL) Dismantling and installation of unit...6 Capacity data...6 Dimensions and weight... 7 Connection diagrams Unit with electric heater...8 Unit with water heater...9 Functions...10 Replacement of room temperature sensor (if applicable)...11 ADJUSTMENT, COMMISSIONING (FOR INSTALLER AND SERVICE PERSONNEL) Settings, Symbol descriptions...12 Parameter lists...13 MISCELLANEOUS Spare parts... 14 EC Declaration of Conformity...15 INFORMATION IN ACCORDANCE WITH ECODESIGN AND REGULATION EU 2016/2281. The ACJB is not B 1, C 2 or C 4 air heating unit. Type of fuel: Electricity. Capacity Other parameters Parameter Designation Value Unit Nominal heating capacity P rated, h 6.0 kw Minimum Capacity P min 0.0 kw Cover losses F env 1.9 % Emission efficiency h s, flow 96.6 % Seasonal efficiency for room heating h s, h 37.9 % WARNING! THE APPLIANCE MAY BE USED BY CHILDREN OVER THE AGE OF 8, PERSONS (INCLUDING CHILDREN) WITH PHYSICAL, SENSORY OR MENTAL DISABILITIES OR LACK OF KNOWLEDGE OR EXPERIENCE, PROVIDED THEY HAVE RECEIVED INSTRUCTION OR INFORMATION ON SAFE USE OF THE APPLIANCE AND UNDERSTAND THE POTENTIAL RISKS. CHILDREN MAY NOT PLAY WITH THE APPLIANCE. CHILDREN MAY NOT CLEAN OR PERFORM MAINTENANCE ON THE APPLIANCE WITHOUT SUPERVISION. NOTE! INSTALLATION, ADJUSTMENT AND COMMISSIONING AS DESCRIBED IN THESE INSTRUCTIONS MUST BE CARRIED OUT BY AN INSTALLER OR SERVICE PERSONNEL.

! Air Heating unit ACJB - Technical manual 3 SYSTEM, FUNCTIONS, MAIN COMPONENTS OVERVIEW OF THE AIR HEATING SYSTEM Air heating unit ACJB Exhaust air Supply air Outdoor air Filter Fan Filter Extract air Toilet Bathroom Scullery Laundry room Kitchen (cooker hood) Filter Hallway or similar central area Fan Heater (water/electric) Warm supply air Other rooms to be heated Heat exchanger Control panel Heat recovery unit Secondary air THE UNIT S MAIN COMPONENTS 1. Coarse filter G3 2. Fine filter M5 3. Secondary air fan SYSTEM DESIGN An air heating system combines air-based heating and balanced ventilation with heat recovery. The heat recovery units can be installed in a kitchen, store room, scullery or attic. An air heating system uses the same ducts for ventilation and heating. CONTROL 1 2 3 4 5 6 4. Control unit 5. Postheater (water/electrical) 6.Casing The control unit automatically controls the ACJB unit s fan and water or electric heater to maintain the desired temperature. SUMMER MODE During the summer months when there is no need for heating, summer mode can be activated. This reduces the fan operation to 30% after a set time delay (normally 24 hours). Summer mode is indicated by a LED on the control panel. Summer mode is automatically deactivated when there is a need for heating. SETTINGS The temperature, fan speed and other parameters are set in consultation with the installer/service personnel. ELECTRICAL DATA UNIT WITH ELECTRIC HEATING Voltage: 400 V, 3-phase, 50 Hz The electric heater operates in two stages: one stage with an output of 3 kw which is controlled steplessly via a pulser, and one fixed stage with an output of 3 kw which is controlled via a contactor. Fan motor Output, W Electric heater Output, W Rated output, W 175 2 x 3,000 6,180 UNIT WITH WATER HEATING Voltage: 230 V, 1-phase, 50 Hz Fan motor output, W Rated output, W 175 180

4 Air Heating unit ACJB - Technical manual CONTROL PANEL RDKZ-41-1, OPERATION CONTROL PANEL RDKZ-41-1 SET DESIRED TEMPERATURE The temperature is set via control panel RDKZ-41-1. Indicates tens (10 90) Indicates ones (1 9) Figure 1. Control panel RDKZ-41-1 with mains lead. The operating mode is selected via the external control panel RDKZ-41-1, which should be installed in a suitable place, either on a wall or in a wall box. Press the arrow button to select operating mode. The activated mode is indicated by a LED. SUMMER MODE NORMAL FORCED FILTER ALARM Each press reduces the set temperature by 1 C Saves the set temperature Each press raises the set temperature by 1 C Figure 3. Setting of desired temperature. 1. Check the current set temperature by pressing either the * or # button once. Then count how many times the NORMAL and FORCED symbols flash. Note that the NORMAL symbol indicates tens and the FORCED symbol indicates ones. Example: If the NORMAL symbol flashes twice and the FORCED symbol flashes three times, the temperature is currently set at 23º C. 2. To change the temperature, press * to reduce it or # to increase it. 3. After setting the desired temperature, press ARROW to save and return to normal mode on the control panel. SUMMER MODE NORMAL Arrow button (for selecting operating mode) FORCED Figure 2. Operating modes on control panel (RDKZ-41-1). NORMAL MODE The air heating unit automatically controls the fan speed to maintain the desired temperature. FORCED MODE The fan goes up to maximum flow. This function can be used to distribute surplus heat through the house, for instance if a heating stove is used. The unit operates in forced mode for 120 minutes, and then returns to NORMAL mode. If forced ventilation is required for only a short time, it can be terminated manually by pressing the arrow button and selecting NORMAL mode.

! Air Heating unit ACJB - Technical manual 5 MAINTENANCE, FILTER REPLACEMENT MAINTENANCE Wipe the unit s casing clean with a cloth. Do not use solvents. The filter should normally be replaced every 6 months, but sometimes more frequent replacement is needed. A timer is set at six months, and the alarm light on the control panel flashes when it is time to replace the filter. To replace the filter, follow the steps below. REPLACEMENT OF FILTERS Power switch Alarm light Fine filter Coarse filter Figure 5. Location of filters in unit. Resetting of filter alarm Figure 4. 1. Switch off the unit with the power switch. 2. Open the filter hatch by turning the knobs. 3. Pull out the filters, see figure 5. 4. Insert new filters. 5. Close the filter hatch. 6. Start the unit. 7. Reset the filter alarm by pressing (*) for at least 10 seconds, see figure 4.

6 Air Heating unit ACJB - Technical manual DISMANTLING AND INSTALLATION, CAPACITY DISMANTLING AND INSTALLATION SECONDARY AIR FAN, AIRFLOW AND PRESSURE DROP Note that the ACJB air heating unit has duct spacers, mounting screw holes, electrical connections and, if applicable, a pipe connection for water heating that is the same as on the previous ACJ unit. 500 q, m 3 /h 100 200 300 400 500 1. Disconnect the unit from the power supply by pulling out the plug or deactivating (removing) the fuse for the unit. 2. Disconnect the unit s duct connections and, if applicable, the pipe connections. 3. Disconnect the unit from the existing mounting studs, mounting brackets and/or silencer box. 4. If there is a room sensor, also disconnect the cables from the room sensor by opening the smaller front hatch and disconnecting them from the circuit board. 5. Dismantle the ACJ unit. 400 300 80% 100% 60 62 64 L wa, db 6. If necessary, clean the secondary air and supply air ducts. 7. Mount the new ACJB unit using the existing mounting devices. 70% 58 8. Connect the ducts and any pipes. 9. Replace the existing room sensor (if applicable) with the room sensor supplied with the new unit. 200 60% 54 56 66 See page 9 for instructions. 10. Install control panel RDKZ-41-1 in a suitable place and connect it to the unit. 11. Switch on the power to the unit.! THE POWER SUPPLY MUST BE SWITCHED OFF WHILE CONTROL PANEL RDKZ-41-1 IS BEING INSTALLED/DISMANTLED. p s, Pa 100 Figure 6. 50% 40% 52 50 10 10 20 30 40 50 60 70 80 90 100 120 140 160 q, l/s 68 To prevent the air flowing in the wrong direction during defrosting, it is recommended to connect a non-return damper between the heat recovery unit and the air heating unit. HEAT OUTPUT FOR UNIT WITH WATER HEATING 4800 4600 4400 4200 P, W 4000 3800 0,06 0,08 0,10 0,12 0,14 0,16 0,18 0,20 0,22 Figure 7. q w, l/s

Air Heating unit ACJB - Technical manual 7 DIMENSIONS AND WEIGHT DIMENSIONS AND WEIGHT Weight: 55 kg 580 125 Ø160 Ø100 = = 290 340 1150 80 140 200 = = Ø120 168 Ø100 Ø120 Figure 8.

8 Air Heating unit ACJB - Technical manual CONNECTION DIAGRAMS UNIT WITH ELECTRIC HEATER N L1 L2 L3 Control panel 9 10 11 12 16 17 N L1 Fan 0 V +10 V 5 67 8 1 23 4 33 32 31 30 18 19 20 21 22 23 24 25 26 27 28 29 GT GT Supply air Return 1 3 5 A2 1 3 A2 Contactor El. heater Contactor Pulser Pulser 2 4 6 A1 2 4 A1 1 2 3 4 6 5 6 5 El. heater 2-ph. 3 kw M 4 3 A 2 1 El. heater 3-ph. 3 kw OK 1 Figure 9.

Air Heating unit ACJB - Technical manual 9 CONNECTION DIAGRAMS, CONT D. UNIT WITH WATER HEATING Power supply Blue Red Brown Valve Control panel TR 1 OK 1 Supply air GT Fan GT Return air Figure 10.

10 Air Heating unit ACJB - Technical manual FUNCTIONS, CONTROL ELECTRIC HEATER 3 + 3 kw When the heating requirement increases, the output signal to the pulser increases within a range of 0-100%. When the output signal reaches 100%, if there is still a need for increased heating, the unit will go into plateau mode for a set time period (plateau time, default = 30 minutes). When the plateau time ends, the fan speed will increase steplessly from MIN to 60% and a new plateau time will start. When the plateau time ends, if there is still need for additional heating, the fixed heating stage of 3 kw will be activated via a contactor and the pulser will regulate the output down to 0%. After this, the pulser increases the output steplessly from 0 till 100% while the fan speed rises from 60% up to MAX. The heat and the fan speed are controlled in parallel. If there is a reduced heating requirement, the pulser will reduce the output from 100 to 0% while the fan speed drops from MAX to 60%. When the pulser reaches 0%, the system will wait for 60 seconds. After the 60 seconds, if there is still a reduced heating requirement, the fixed heating stage will be deactivated and the pulser regulates the output down from 100% to 0%. When the output drops below 75%, the fan speed will drop steplessly from 60% to MIN. HIGH SUPPLY AIR TEMPERATURE If the supply air temperature rises above 55 C, the pulser will immediately be deactivated. When the supply air temperature drops below 55 C, the pulser is immediately reactivated. If the supply air temperature rises above 65 C, the fixed heating stage will immediately be deactivated. When the supply air temperature drops below 65 C, the fixed heating stage is reactivated after 60 seconds. QUICK HEATING FUNCTION If the temperature setpoint is set to MAX (30 C), the fan speed and the temperature will immediately increase to 100%. This quick heating function is manual and has no automatic stop time or temperature limitation. When the desired temperature is reached, the setpoint should be reset manually (approx. 20 C). SUMMER MODE The SUMMER parameter (default = 0, off) is used to set the amount of time that elapses before Summer mode is activated when no heating is needed. The time delay is set in whole hours. The recommended value is 24 hours. When the set time (24 hours without a heating requirement) expires, the fan speed drops to 30% (fixed fan speed). Summer mode is indicated by a LED on the control panel (see figure 11). When the regulator signals a demand for heating (over 5%), Summer mode is deactivated and the fan resumes Normal mode. SUMMER MODE OVERHEATING The automatic overheating protection is activated when the heater reaches a temperature of 90 C and is deactivated at approx. 50 C. The automatic overheating protection only cuts the heat supply. The fan will continue operating. The manually resettable overheating protection is activated when the heater reaches a temperature of approx. 120 C and can be reset at approx. 75 C. The manually resettable overheating protection cuts both the heat supply and the fan function. No indication is shown on the control panel if the overheating protection has tripped. WATER HEATER When the heating requirement increases, the output signal to the pilot valve increases. When the output signal reaches 50%, if there is still a need for increased heating, the unit will go into plateau mode for a set time period (PLATEAU TIME, default =30 min.). When the plateau time ends, the fan speed will increase steplessly from MIN to MAX and the heating signal will simultaneously increase from 50% to MAX. The heat and the fan speed are controlled in parallel. If there is a reduced heating requirement, the control valve will regulate the output from 100 to 50% while the fan speed drops from MAX to MIN. After this, the output signal to the control valve will continue decreasing from 50% down to 0%. SETPOINT The setpoint can be set via the panel between +10 and +30 C. The setpoint is always saved automatically in EEPROM, regardless of whether it is changed via the parameter list or via quick setting. An external potentiometer (optional accessory) can be connected to the vacant temperature contact next to the two temperature sensors. The board automatically detects the connected potentiometer and reads the setpoint from it. The current setpoint can be read from the panel, but it cannot be changed from the panel. The potentiometer can be removed at any time, even while the power is switched on. If it is removed, the function will return to the panel (plug and play). FILTER ALARM The dirty filter alarm counts 180 days before the red light flashes. To acknowledge the alarm, depress the left button (star) for 10 seconds. The filter alarm is activated by default (parameter 7 = 1). The alarm can be deactivated (parameter 7 = 2). TEMPERATURE SENSOR MALFUNCTION If a temperature sensor becomes faulty, the heat supply will be blocked completely but the fan will continue operating. A temperature error will not be indicated. START-UP On start-up, the fan will run at maximum speed for 8 seconds and then run at NORMAL speed. Figure 11. Indication of SUMMER MODE.

! Air Heating unit ACJB - Technical manual 11 REPLACEMENT OF ROOM TEMPERATURE SENSOR (IF APPLICABLE) If the old ACJ unit has a room temperature sensor, the sensor cannot be used in the new ACJB unit. A new room temperature sensor (optional accessory) must be installed in the new unit. 1. Disconnect the unit from the power supply. 2. Remove the old room sensor. 3. Connect the room temperature sensor to the existing room temperature cable from the old unit. 4. Connect the room temperature cable to the junction box on the short side of the unit (see figure 12). First remove the protective cover. Connect the ends of the cables, then reconnect the protective cover. 1 Figure 12. Junction box for cable from room temperature sensor. 5. On the control unit s terminal block, replace the cable from the temperature sensor in the unit s inlet with the cable coming out of the junction box on the short side of the unit (the cable from the new room temperature sensor) with the white marking. See figure 13. 6. Switch on the power to the unit. 2 Figure 13. Replacement of cable on the control unit s terminal block.

12 Air Heating unit ACJB - Technical manual SETTINGS, SYMBOL DESCRIPTIONS SETTINGS To change a parameter, follow the instructions below. Also see the parameter list and figure 15. 1. Always start from normal operating mode. 2. Activate reading mode by depressing * and # simultaneously for about 3 seconds. The parameter number is illustrated by the number of times the alarm symbol flashes. See the parameter list provided. 3. Switch between the parameters by pressing * (previous) and # (next). 4. To change a current parameter s value, depress * and # simultaneously again for roughly 3 seconds until the alarm light is steadily illuminated. 5. The parameter value can now be adjusted by pressing * (reduce) and # (increase). The parameter value is illustrated by the number of times the green LEDs flash (see table 16). 6. Confirm the change by pressing the ARROW button. 7. To change more parameters, repeat the procedure above. To restore the factory settings, depress * and # simultaneously for more than 15 seconds. When all the LEDs flash simultaneously, confirm the reset by pressing the arrow button. Note: If you do not press the arrow button, only the setpoint will be reset to 20 C. Lowers the set value in programming mode Figure 14 Symbols on display Raises the set value in programming mode Arrow button (CONFIRM/SAVE) NOTE! THE MINIMUM FAN SPEED MUST BE INCREASED DEPENDING ON THE SIZE OF THE HOME. AMONG OTHER THINGS, THIS PREVENTS THE OVERHEATING PROTECTION FROM TRIPPING. SYMBOL DESCRIPTION FOR CONTROL PANEL RDKZ-41-1 WHEN MAKING ADJUSTMENTS Symbol Reading mode Adjustment mode The number of times the alarm symbol flashes indicates which parameter is displayed. See the parameter list below. Steady illumination indicates that adjustment mode is active and that the current parameter value can be changed A flashing light indicates hundreds A flashing light indicates tens A flashing light indicates tens A flashing light indicates ones A flashing light indicates ones Table 15.

Air Heating unit ACJB - Technical manual 13 PARAMETER LISTS ELECTRIC HEATER 3 + 3 kw Parameter Function Setting Factory setting 1 Setpoint value supply air C 10 30 20 2 Current temperature supply air C Display 3 Current temperature secondary air C Display 4 Summer mode 0=no 1-255=number of hrs before activation 0 255 0 5 Adjustment MIN speed in % 40 60 40 6 Adjustment MAX speed in % 40 100 100 7 Filter alarm 1=Yes 2=No 1 2 1 8 Plateau time in minutes before changing the fan speed and heat output 0 255 30 9 Internal function 10 P-band multiplier 1 255 8 11 Int action time 1=5min 1 255 10 12 Current register value Display 13 Current bit information Display WATER HEATER Parameter Function Setting Factory setting 1 Setpoint value supply air C 10 30 20 2 Filter alarm 1=Yes 2=No 1 2 1 3 Adjustment MIN speed in % 40 100 40 4 Adjustment MAX speed in % 40 100 100 5 Current temperature supply air C Display 6 Current temperature extract air C Display 7 P-band multiplier 1 255 8 8 Int.action time 1=5 min. 1 255 10 9 P-band VA multiplier (not used) 1 255 8 10 Int. action time VA 1=5 min. (not used) 1 255 10 11 Range 0 200 100 12 Plateau time in minutes before changing the fan speed and heat output 13 Summer mode (not used) 0 255 14 Control type electric/water (not used) 0 255 30

! 14 Air Heating unit ACJB - Technical manual REPLACEMENT PARTS 4 8 7 4 1 5 2 3 6 Pos. Designation Name Included in Quantity 1 ACJZ-01 Coarse filter ACJB, G3 ACJB 5 1 ACJZ-02 Fine filter ACJB, M5 ACJB 2 1 ACJZ-03 Filter kit ACJB, G3 + M5 ACJB 1 2 ACJB-99-21 Fan, complete EC 175 W ACJB 1 3 ACJB-99-15 Control board, electric heater 3 + 3 kw ACJB-aa-b-c-1-e 1 3 ACJB-99-16 Control board, electric heater 6 kw ACJB-aa-b-c-1-e 1 3 ACJB-99-17 Control board, water heater ACJB-aa-b-c-5-e 1 4 ACJB-99-08 Temperature sensor kit, 1+1 ACJB 1 5 CPDC-99-01 Switch ACJB 5 6 ACJB-99-11 Electric heater 3 + 3 kw ACJB-aa-b-c-1-e 1 6 ACJB-99-12 Electric heater 6 kw *) (conversion kit 3 + 3 kw) ACJB-aa-b-c-1-e 1 6 ACJB-99-02 Water heater ACJB-aa-b-c-5-e 1 7 ACJB-99-05 Pulser ACJB-aa-b-c-1-e 1 8 ACJB-99-06 Contactor ACJB-aa-b-c-1-e 1 9 ACJB-99-03 Valve actuator ACJB-aa-b-c-5-e 1 10 ACJB-99-07 Transformer 230/24V ACJB-aa-b-c-5-e 1 *) Electric heater 6 kw has been discontinued. It has been replaced with electric heater 3 + 3 kw including conversion kit. If the supply cord is damaged, it must be replaced by the manufacturer, an authorised service firm or a similarly qualified professional in order to avoid hazard.

FG_DC_9170GB_Heatmaster ACJB_IN-MA-CM-SP_20181004_R1 Copyright 2018 FläktGroup J8016030-2301 WWW.FLAKTGROUP.COM HEATMASTER ACJB FläktGroup is the European market leader in smart, energy-efficient ventilation systems for optimal indoor comfort, critical applications and fire safety. Our products and solutions are based on innovative technology, high quality and superior performance, backed by over 100 years of experience in the industry. With the market s widest range of products and strong market presence in 65 countries worldwide, we are always close to you with a clear focus on delivering Excellence in Solutions. FLÄKTGROUP PRODUCT AREAS Air Treatment Air Movement Air Distribution Chilled Beams & Chilled Beam Cassettes Air FiltrationAir Management & ATDs Air Conditioning & Heating Control Service» Learn more on www.flaktgroup.com or contact one of our offices