CaptiveAire Sloped Installation Manual
Standard and Modular Electric Heaters and Inserts
Installation, Operation, and Maintenance Manual
Modular Electric Heater
Electric Heat Module
Electric Duct Insert
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RECEIVING AND INSPECTION
WARNING!!
Upon receiving unit, check for any interior and exterior damage, and if found, report it
immediately to the carrier. Also check that all accessory items are accounted for and are
damage free. Turn the blower wheel by hand to verify free rotation and check the damper (if
supplied) for free operation.
Installation of this ventilator should only be performed by a qualified professional who has
read and understands these instructions and is familiar with proper safety precautions.
Improper installation poses serious risk of injury due to electric shock, contact with rotating
equipment and other potential hazards. Read this manual thoroughly before installing or
servicing this equipment. ALWAYS disconnect power prior to working on fan.
. This document is the property of the owner of this equipment and is
required for future maintenance. Leave this document with the owner when installation or
service is complete.
A0011031
April 2011 Rev. 13
TABLE OF CONTENTS
WARRANTY .................................................................................................................................................. 4
INSTALLATION ............................................................................................................................................. 5
Mechanical ................................................................................................................................................ 5
Site Preparation .................................................................................................................................... 5
Intake Assembly ................................................................................................................................... 5
Curb and Ductwork ............................................................................................................................... 5
Recommended Supply Ductwork Sizes ............................................................................................... 5
Roof Mount Installation ......................................................................................................................... 6
Installation with Exhaust Fan ................................................................................................................ 6
Duct Mount Installation ......................................................................................................................... 7
Indoor (INLINE) Installation .................................................................................................................. 7
Heat Module Add-On Installation ......................................................................................................... 7
Electrical ................................................................................................................................................... 8
Copper Wire Ampacity ......................................................................................................................... 8
PSC (Permanent Split Capacitor) Motor Speed Control ...................................................................... 9
ECM (Electronically Controlled Motor) Speed Control ......................................................................... 9
Motorized Intake Damper ..................................................................................................................... 9
Remote Control Panel ........................................................................................................................ 10
Fan to Building Wiring Connection ..................................................................................................... 10
OPERATION ............................................................................................................................................... 11
Start Up ................................................................................................................................................... 11
Special Tools Required ...................................................................................................................... 11
Start Up Procedure ............................................................................................................................. 11
Pulley Adjustment ............................................................................................................................... 12
Pulley Alignment ................................................................................................................................. 12
Proper Belt Tension ............................................................................................................................ 12
Pulley Setscrew Torque ..................................................................................................................... 12
Pulley Combination Chart ................................................................................................................... 13
Sequence of Operation ........................................................................................................................... 14
Main Circuit ......................................................................................................................................... 14
Optional Remote Panel Circuit ........................................................................................................... 15
Components............................................................................................................................................ 16
Remote Panel Option ......................................................................................................................... 17
Modulating Coil Thermostat Dip Switch Settings ............................................................................... 18
Step Controller Coil Thermostat Dip Switch Settings ......................................................................... 18
Troubleshooting ...................................................................................................................................... 19
Troubleshooting Chart ........................................................................................................................ 19
Remote Panel Troubleshooting Chart ................................................................................................ 20
MAINTENANCE .......................................................................................................................................... 21
General Maintenance ............................................................................................................................. 21
2 weeks after startup .............................................................................................................................. 21
Every 3 months ....................................................................................................................................... 22
Filter Quantity Chart ........................................................................................................................... 22
Yearly ...................................................................................................................................................... 22
Start-Up and Maintenance Documentation ............................................................................................ 24
Job Information ................................................................................................................................... 24
Heater Information .............................................................................................................................. 24
Maintenance Record .......................................................................................................................... 24
Factory Service Department ............................................................................................................... 24
3
WARRANTY
This equipment is warranted to be free from defects in materials and workmanship, under normal use and
service, for a period of 12 months from date of shipment. This warranty shall not apply if:
1. The equipment is not installed by a qualified installer per the MANUFACTURER’S installation
instructions shipped with the product,
2. The equipment is not installed in accordance with federal, state and local codes and regulations,
3. The equipment is misused or neglected,
4. The equipment is not operated within its published capacity,
5. The invoice is not paid within the terms of the sales agreement.
The MANUFACTURER shall not be liable for incidental and consequential losses and damages
potentially attributable to malfunctioning equipment. Should any part of the equipment prove to be
defective in material or workmanship within the 12-month warranty period, upon examination by the
MANUFACTURER, such part will be repaired or replaced by MANUFACTURER at no charge. The
BUYER shall pay all labor costs incurred in connection with such repair or replacement. Equipment shall
not be returned without MANUFACTURER’S prior authorization and all returned equipment shall be
shipped by the BUYER, freight prepaid to a destination determined by the MANUFACTURER.
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INSTALLATION
It is imperative that this unit is installed and operated with the designed airflow and electrical supply in
accordance with this manual. If there are any questions about any items, please call the service
department at 1-866-784-6900 for warranty and technical support issues.
Mechanical
WARNING: DO NOT RAISE VENTILATOR BY THE INTAKE HOOD, BLOWER,
MOTOR SHAFT OR BEARINGS – USE LIFTING LUGS PROVIDED OR A SLING
Site Preparation
1. Provide clearance around installation site to safely rig and lift equipment into its final position.
Supports must adequately support equipment. Refer to manufacturer’s estimated weights.
2. Consider general service and installation space when locating unit.
3. Locate unit close to the space it will serve to reduce long, twisted duct runs.
4. Do not allow air intake to face prevailing winds. Support unit above ground or at roof level high
enough to prevent precipitation from being drawn into its inlet. The inlet must also be located at
least 10 feet away from any exhaust vents. The heater inlet shall be located in accordance with
the applicable building code provisions for ventilation air.
Intake Assembly
Intakes are shipped on a separate skid. Upon unit arrival, follow the following procedure to assemble the
intake to the fan
1. Apply silicone or weather-proof gasket on
the back side of the flanges of the intake
hood or v-bank intake.
2. Screw the flanges of the intake hood to the
unit with the supplied sheet metal screws.
Place caulk on the outside of the screws to
prevent water leaks. If the unit is a modular
unit with a v-bank or evaporative cooler
section, the v-bank or evaporative cooler will
bolt to the heater with the bolts provided.
Curb and Ductwork
This fan was specified for a specific CFM and static pressure. The ductwork attached to this unit will
significantly affect the airflow performance. Flexible ductwork and square elbows should not be used.
Also, transitions and turns in ductwork near the fan outlet will cause system effect and will drastically
increase the static pressure and reduce airflow. The chart below shows the minimum fan outlet duct
sizes and straight lengths recommended for optimal fan performance. Follow SMACNA guides and
recommendations for the remaining duct run. Fans designed for rooftop installation should be
installed on a prefabricated or factory built roof curb. Follow curb manufacturer’s instructions for proper
curb installation. The unit should be installed on a
curb and/or rail elevated not less than 20” above
any surface. Be sure duct connection and fan
outlet are properly aligned and sealed. Secure fan
to curb through vertical portion of the ventilator
base assembly flange using a minimum of eight
(8) lug screws, anchor bolts, or other suitable
fasteners (not furnished). Shims may be required
Recommended Supply Ductwork Sizes
Blower Size Duct Size Straight Duct Length
10 14 x 14 48 in.
15 20 x 20 72 in.
18 24 x 24 86 in.
20 26 x 26 108 in.
25 32 x 32 168 in.
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depending upon curb installation and roofing material. Check all fasteners for tightness. The diagrams
below show different mechanical installation configurations.
Roof Mount Installation
Installation with Exhaust Fan
6
Duct Mount Installation
Indoor (INLINE) Installation
Heat Module Add-On Installation
Modular heat units shipped to add heat onto existing blower only applications require field mechanical
and wiring installation.
1. Remove existing filter intake and lifting lugs from blower section intake side.
2. Attach heat module to blower intake using the provided sheet metal screws and bolts. Tighten
screws and bolts securely to compress the gasket between the heat module and the blower
module.
3. Support and level the end of the heat
module (end opposite the blower) with
the provided equipment legs/rails.
4. Attach the filter hood to the intake side
of the heater module.
5. Drill a hole in the discharge of the
blower large enough to insert the
discharge control thermostat (if
provided). Install the sensor in the
drilled hole.
6. Wire the sensor and coil as indicated
on the supplied wiring schematic. Run
all wiring within metal conduit.
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Copper Wire Ampacity
Electrical
WARNING!!
Before connecting power to the heater, read and understand
this entire section of this document. As-built wiring diagrams
are furnished with each fan by the factory, and are attached to
the door of the unit.
Electrical wiring and connections should be done in accordance
with local ordnances and the National Electric Code,
ANSI/NFPA70. Be sure the voltage and phase of the power
Disconnect power before
installing or servicing fan. High
voltage electrical input is
needed for this equipment. This
work should be performed by a
qualified electrician.
supply and the wire amperage capacity is in accordance with
the motor nameplate. For additional safety information refer to AMCA publication 410-96, Recommended
Safety Practices for Users and Installers of Industrial and Commercial Fans.
WARNING: ELECTRIC HEATERS HAVE TWO POWER INPUTS. THE EXTERNAL
DISCONNECT INTERRUPTS POWER TO THE MOTOR AND CONTROLS ONLY.
THE ELECTRIC COIL POWER IS INTERRUPTED BY THE DISCONNECT SWITCH
ON THE ELECTRIC COIL DOOR.
1. Always disconnect power before working on or near a
heater. Lock and tag the disconnect switch or breaker to
prevent accidental power up.
2. An electrical drop containing the motor power wiring is
shipped with every fan. The electrical drop should be brought
through one of the conduit openings located in the base of the
unit, run through the curb, and connected to a junction box
inside the building.
3. A dedicated branch circuit should supply the motor circuit with
short circuit protection according to the National Electric Code.
This dedicated branch should be run to the junction box
mentioned above and connected as shown in a following
illustration labeled “Fan to Building Wiring Connection”.
4. A separate power source should supply the electric coil
power. Power from the building breaker should be wired
directly to the coil disconnect. This should be done using wire
of the proper gauge as indicated on the wire ampacity chart to
Wire Size AWG Maximum Amps
14 15
12 20
10 30
8 50
6 65
4 85
3 100
2 115
1 130
1/0 150
2/0 175
3/0 200
4/0 230
250 255
300 285
350 310
400 335
500 380
600 420
the right. A hole must be drilled in the fan enclosure to
properly run the electric coil power.
5. Make certain that the power source is compatible with the requirements of your equipment. The
heater nameplate identifies the proper phase and voltage of the motor and coil.
6. Units shipped with an optional remote panel have two electrical circuit drops. It is important to
run the motor wires in a separate conduit from the remote control wiring. The DC wires from the
unit temperature controller, located in the control drop, should be shielded cable or run in a
separate conduit.
7. Before connecting heater to the building power source, verify power line wiring is de-energized.
8. Secure the power cables to prevent contact with sharp objects.
9. Do not kink power cable and never allow the cable to come in contact with oil, grease, hot
surfaces or chemicals.
10. Before powering up the heater, check fan wheel for
free rotation and make sure that the interior of the
heater is free of loose debris or shipping materials.
11. If any of the original wire supplied with the heater
must be replaced, it must be replaced with type
THHN wire or equivalent.
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