Flagro FLE-60 Operating Instructions Manual

OPERATING INSTRUCTIONS MANUAL

INDUSTRIAL / COMMERCIAL ELECTRIC HEATER

FLE-60

(OPERATOR MUST RETAIN FOR FUTURE REFERENCE)

Suitable for indoor or outdoor installation / Unvented / Unattended Type

26 Benfield Drive, St.Catharines, Ontario Canada L2S 3V5

(P) 905-685-4243 - (F) 905-685-0113

FLE-60 OPERATING INSTRUCTIONS MANUAL

GENERAL HAZARD WARNING:

FAILURE TO COMPLY WITH THE PRECAUTIONS

AND INSTRUCTIONS PROVIDED WITH THIS

HEATER, CAN RESULT IN DEATH, SERIOUS

BODILY INJURY AND PROPERTY LOSS OR

DAMAGE FROM HAZARDS OF FIRE, EXPLOSION

BURN ASPHYXIATION, OR ELECTRICAL SHOCK

ONLY PERSONS WHO CAN UNDERSTAND AND

FOLLOW THE INSTRUCTIONS SHOULD USE OR

SERVICE THIS HEATER.

IF YOU NEED ASSISTANCE OR HEATER

INFORMATION SUCH AS AN INSTRUCTIONS

MANUAL, LABEL, ETC. CONTACT THE

MANUFACTURER

WARNING: FIRE, BURN, INHALATION

AND EXPLOSION HAZARD, KEEP SOLID

COMBUSTIBLES, SUCH AS BUILDING

MATERIALS, PAPER, OR CARDBOARD, A SAFE

DISTANCE AWAY FROM THE HEATER AS

RECOMMENDED BY THE INSTRUCTIONS

NEVER USE THE HEATER IN SPACES WHICH DO

OR MAY CONTAIN VOLATILE OR AIRBORNE

COMBUSTIBLES, OR PRODUCTS SUCH AS

GASOLINE SOLVENTS, PAINT THINNER, DUST

PARTICLES OR UNKNOWN CHEMICALS

WARNING: NOT FOR HOME OR

RECREATIONAL VEHICLE USE

Introduction

Quality

: The FLE-60 is built with the highest quality of components giving our

Convenience:

The FLE-60 gives our customers the flexibilty of a 20kW/40kW/60kW heat setting.

You have just received an FLE-60 60kW Electric Construction Heater manufactured by Flagro Industries.
Use: The FLE-60 Electric Construction Heater is designed for temporary heat only.

The heater may be installed indoors or out and used to bring 100% outdoor air, or heat
and re-circulate building air. The FLE-60 is designed to heat large spaces, buildings
and machines without worrying about on site fuel.

customers the confidence they deserve in a Flagro product.

The heater is equipped with a fan speed inverter control that provides optimum temperature rise
by adjusting blower output at each heat setting. Colour coded Cam Locks power connections
for easy installation. Remote thermostat option available.

Inlet Duct Adapter

The FLE-60 includes a permanant inlet duct adapter.

Heater manufacturer approved ducting must be attached for outdoor use.

Safety

Always verify that you have proper voltage supply. (480V) It is important to check
the wiring connections inside the heater before plugging in the Cam Locks.
Use a meter to measure volt supply to each cam lock.
Work on the internal systems should only be attempted by a certified electrician and
only when power has been disconnected and can not be reconnected to the heater.

Grounding

The heater is supplier with a cam lock system with a grounding connection and is indicated with a "G"
on the cam lock panel. The heater is also supplied with a grounding nuts found on all panels.
It is very important to double check that all grounding connections are properly secure.

Clearance from Combustibles

The discharge temperature of these units may reach very high temperatures. Maintain minimum
distance from combustible materials as follows:

Top: 6 Inches

Bottom: 6 Inches
Sides: 6 Inches
Discharge: 15 FT

MAINTENANCE

1 Every heater should be inspected before each use, and at least annually by a

qualified service person

2 The appliance must be kept clear and free from combustible materials,

gasoline and other flammable vapors and liquids

3 The flow of ventilation air must not be obstructed.

Be sure to check the fan assembly and ensure the motor and blade
are operating properly and it is important to clean air filters

4 Compressed air may be used to keep components free of dust and dirt

build up.

Pre-Start Checklist

1

Heater must be level and lockable wheels must be in the lock position

2

Make sure blower switch and both heat switches are in the "OFF" positions

3

Make sure the air intakes are free from any obstruction(s)

4

Make sure the heater oulet is free from any obstruction(s)

5

Make sure the heater is properly grounded

6

Check power supply voltage and ampacity

7

If using the heater outdoors, heater manufacturer approved ducting must be attached to heater.

START UP INSTRUCTIONS

1 Determine power source - 480V (confirm power source is correct)

2 Remove top cover and inspect all wiring

(once complete, secure top cover to heater using the same hardware)

3 Connect Flanged Camlocks to female camlocks ( colour coded)

Connect camlocks as follows:

Red A

Black B

Blue C

Ground G

3 PHASE UNIT CONNECTION

4 Turn on power supply

5 Pull "Master" button to the out position

6 Determine "Manual" or Remote Thermostat (if remote, set desired temperature)

7 Turn Blower on/off switch to the "ON" position

(The blower will start and the green air flow light will come on)

8 Turn on heater settings as desired

( 60kW= 20kW & 40kW combined)

Failure to have proper air flow will cause unit to overheat and shut down

The green light should come on and air should be pushed through the outlet port
Check to see that only the green light is on.

Caution: Heater body panels will get very hot

Notes:

Speed inverter is pre-set for optimum air flow/temperature rise.

HEAT SETTING

BTUH

CFM

TEMP. RISE

NOISE RATING

1

2

3

4

5

6

7

Based on kW selection, blower will adjust speed. See Chart below

60 kW 205,000 3300 110DEG F/43DEG C 67 DB

40 kW 164,000 2800 85DEG F/30DEG C 63 DB

20kW 82,000 2450 50DEG F/10DEG C 63DB

FAN ONLY 3900 71DB

SHUTDOWN

Move all heater setting controls to the "OFF" position

Leave Fan in the "ON" position for 3-5 minutes

Turn Fan OFF
( blower is preset to run for 30 seconds before coming to a complete stop)

Push Master button "IN"

Shut off all power source

Disconnect all power sources

Store heater

26 Benfield Dr. St.Catharines, Ontario Canada L2S 3V5

(O) 905-685-4243 (F) 905-685-0113

HEATER SPECIFICATIONS

MODEL FLE-60

Power Requirements

MAXIMUM INPUT (KW)

BLOWER

TEMPERATURE RISE

AMP DRAW

DB (noise level)

(above ambient)

480V

205,000 btu

1 1/2 H.P.

20KW 50 DEG F

40KW 85 DEG F

60 KW 110 DEG F

MOTOR

20KW

40KW

60KW

FAN ONLY

20KW

40KW

60KW

3 AMPS

28 AMPS

40 AMPS

68 AMPS

71DB

63DB

63DB

67 DB

INLET SIZE
OUTLET SIZE

(Designed for 20" Dia. Ducting)

DIMENSIONS

H X L X W (IN.)

WEIGHT

AIR CIRCULATION

16" X 16"
18" x 13"

32 X 48 X 25 1/2

290 LBS. (unboxed)

3900 CFM

FLE-60– PARTS LIST

60KW RESISTOR ELEMENT

FLE-601 (480 VOLT)

VARIABLE SPEED DRIVE

FAN BLADE ASSEMBLY

FLE-602

FAN BELT

1.5 HP MOTOR

FLE-603 (480 VOLT)

PULLEYS

FLE-604 (480 VOLT)

FUSES

FLE-628 - 60 amp class T
FLE-629 – 30amp class T
FLE-630 - 5amp class CC
FLE-631 - 1/2amp class CC
FLE-632 - 5amp AGC - glass

FLE-620

TRANSFORMER

FLE-627 – 480V

FLE-608 – 3.25” PULLEY
FLE-607 – 7” PULLEY

GROUNDING BLOCK

FLE-621

FLE-60 PARTS LIST

RELAY

FLE-626

(2 PER UNIT)

SAIL SWITCH

CONTACTORS

FLE-625 – 32A 3P
FLE-624 – 65A 3P

2 POSITION SWITCH

HIGH LIMIT

FLE-623 ( 200F)

EMERGENCY STOP BUTTON

FLE-641

GREEN AIR PROVEN LIGHT

FLE-636

FLE-633

20KW
40KW
THERMOSTAT/MANUAL
BLOWER ON/OFF

HIGH LIMIT/AIR PROVEN LIGHT

FLE-635

FLE-634

THERMOSTAT

FV-414B

FLE-60 PARTS LIST

N/C CONTACT BLOCK N/O CONTACT BLOCK

FLE-639

(3 PER UNIT)

CAM-LOCK - PANEL

SNAP COVERS - PANEL

FLE-640

(7 PER UNIT)

CAM-LOCK DETACHABLE

FLE-615 – BLUE
FLE-616 – BLACK
FLE-617 – GREEN
FLE-618 - RED

WHEELS

FLE-611 – BLUE
FLE-612 – BLACK
FLE-613 – GREEN
FLE-614 - RED

FLE-611A – BLUE
FLE-612A – BLACK
FLE-613A – GREEN
FLE-614A - RED

FLE-609 – 6” LOCKABLE
FLE-610 – 6” RIGID

BODY PANELS

P/N DESCRIPTION

FEH-60FR OUTER FRAME

FEH-616 TOP PANEL

FEH-611C LEFT SIDE PANEL

FEH-610C RIGHT SIDE PANEL

FEH-612C FRONT PANEL

FEH-614 REAR SIDE PANEL

FLE-170 CONTROL PANEL RAIN GUARD

PARTS LIST FOR FLE-60

Part Number Part Description

FLE-601 60KW RESISTOR ELEMENT (480 VOLT)

FLE-602 FAN BLADE ASSEMBLY

FLE-603 1-1/2 HP MOTOR (480 VOLT)

FLE-604 VARIABLE SPEED DRIVE (480 VOLT)

FLE-605 WIRED CONTROL/OPERATOR PANELS (480 VOLT)

FLE-606 ADJUSTABLE MOTOR BASE

FLE-607 7" FAN PULLEY

FLE-608 3.25" MOTOR PULLEY

FLE-609 6" LOCKABLE SWIVEL CASTER FOR FLE-60 (TWO REQUIRED)

FLE-610 6" RIGID CASTER (TWO REQUIRED)

FLE-611 BLUE MALE PANEL CAM-LOCK

FLE-611A BLUE SNAP COVER

FLE-612 BLACK MALE PANEL CAM-LOCK

FLE-612A BLACK SNAP COVER

FLE-613 GREEN MALE PANEL CAM-LOCK

FLE-613A GREEN SNAP COVER

FLE-614 RED MALE PANEL CAM-LOCK

FLE-614A RED SNAP COVER

FLE-615 BLUE FEMALE DETACHABLE CAM-LOCK

FLE-616 BLACK FEMALE DETACHABLE CAM-LOCK

FLE-617 GREEN FEMALE DETACHABLE CAM-LOCK

FLE-618 RED FEMALE DETACHABLE CAM-LOCK

FLE-619 LIFTING LATCH (FOUR REQUIRED)

FLE-620 FAN BELT

FLE-621 GROUNDING BLOCK

FLE-622 DISTRIBUTION BLOCK

FLE-623 OUTLET HIGH LIMIT - 200 F

FLE-624 CONTACTOR - 65A 3P

FLE-625 CONTACTOR - 32A 3P

FLE-626 DAYTON CUBE RELAY (TWO REQUIRED)

FLE-627 480 VOLT TRANSFORMER

FLE-628 60 AMP CLASS T FUSE (THREE REQUIRED)

FLE-629 30 AMP CLASS T FUSE (THREE REQUIRED)

FLE-630 5 AMP CLASS CC TIME DELAY (THREE REQUIRED)

FLE-631 1/2 AMP CLASS CC TIME DELAY (TWO REQUIRED)

FLE-632 5 AMP AGC GLASS FUSE

FLE-633 TWO POSITION SWITCH (FOUR PER HEATER)

FLE-634 EMERGENCY STOP BUTTON

FLE-635 RED HIGH LIMIT/NON-PROVEN AIR LIGHT (TWO PER HEATER)

FLE-636 GREEN AIR PROVEN LIGHT

FLE-637 BULBS FOR FLE-635 & FLE-636 (THREE PER HEATER)

FLE-638 OPERATOR BLOCK FOR FLE-635 & FLE-636

FLE-639 N/C CONTACT BLOCK (THREE PER HEATER)

FLE-640 N/O CONTACT BLOCK (SEVEN PER HEATER)

FLE-641 SAIL SWITCH (COMPLETE)

FLE-642 INTERNAL FILTER (TWO PACK)

FV-414B THERMOSTAT CONNECTION

VFD (VARIABLE FREQUENCY DRIVE)

EVERY FLE SERIES HEATER IS EQUIPPED WITH A “VFD”
VARIABLE FREQUENCY DRIVE. THE VFD HAS BEEN PRE
PROGRAMMED WITH THE FOLLOWING SETTINGS:

HEAT SETTING AIR SPEED Hz

FLE-60 (20 KW) 40Hz (2450 CFM)

FLE-60 (40 KW) 45Hz (2800 CFM)

FLE-60 (60 KW) 50Hz (3300 CFM)

FLE-60 (FAN ONLY) 60Hz (3900 CFM)

Troubleshooting

THE VFD HAS BEEN PASSWORD PROTECTED WITH THE PREPROGAMMED SETTINGS. THESE SETTINGS
ARE THE “MINIMUM” AIR FLOW REQUIRED, THE CHART BELOW PROVIDES THE PARAMETER FOR EACH

AIR FLOW SETTING:

VFD PARAMETER CODE SETTING

P133 FAN ONLY AIRFLOW (FLE-60)

P131 20KW (FLE-60) AIRFLOW

P132 40KW (FLE-60) AIRFLOW

P134 60KW (FLE-60) AIRFLOW

VFD (VARIABLE FREQUENCY DRIVE)

THE FOLLOWING PAGES ARE FOR REFERENCE OF WARNING OR FAULT MESSAGES THAT MAY APPEAR ON

THE SCREEN OF THE VFD. IF ANY OF THE MESSAGE DO APPEAR, PLEASE REVIEW THE VFD MANUAL OR
CONTACT FLAGRO INDUSTRIES TO HELP CORRECT THE ISSUE. TO REVIEW FAULT HISTORY, PASSWORD

MUST BE ENTERED AND GO TO P500 FOR HISTORY

VARIABLE FREQUENCY DRIVE- STATUS/WARNING MESSAGES

VARIABLE FREQUENCY DRIVE- FAULT MESSAGES

TROUBLESHOOTING

PULL MASTER SWITCH ON, NO RED LIGHT
“NON-PROVEN”

TRY BLOWER SWITCH, IF BLOWER ENGAGES,
TURN POWER OFF & TEST RED “NON-PROVEN”
LIGHT CONTACT BLOCK. SHUT POWER OFF TO
HEATER, TEST OHMS RESISTANCE ACROSS
CONTACT BLOCK. IF OHMS RESISTANCE GOOD,
FAULTY BULB

IF BLOWER DOES NOT ENGAGE, CHECK OUTPUT
POWER ON TRANSFORMER, SHOULD BE 120
VOLTS. IF NO POWER, TURN POWER OFF AND
CHECK FU1 (5A)FUSE, IF GOOD, CHECK FB4 (.5 A)
FUSES FOR CONTINUITY

IF TRANSFORMER HAS PROPER OUTPUT POWER,
CHECK VFD SCREEN FOR COMMAND. SHOULD
READ “STOP” BEFORE COMMAND. LOOK FOR
FAULT CODES ON SCREEN. REFER TO VFD FAULT
MESSAGE CHART. YOU CAN ALSO CHECK OHMS
RESISTANCE ACROSS CONTACT BLOCKS ON
BACK OF BLOWER SWITCH. BLOCK WITH RED
WIRES-CONTACTOR CONTROL, BLOCK WITH
YELLOW WIRES- VFD CONTROL. ALWAYS HAVE
POWER OFF TO TEST OHMS

UNIT WILL NOT “PROVEN” AIR, NO GREEN
LIGHT AFTER ENGAGING BLOWER FAN
SWITCH

WILL THE HEAT ENGAGE? IF NOT, CHECK AIR
SAIL SWITCH ,TRY TO BYPASS SWITCH TO
DETERMINE IF FAULTY. SHUT POWER OFF,
BYPASS SWITCH, THEN TURN POWER ON FOR
TEST.

INSPECT INTAKE AIR FILTER(S) CLEAN IF
REQUIRED

UNIT PROVES AIR, BLOWER RUNS, BUT
HEAT WILL NOT ENGAGE.

CHECK OHMS RESISTANCE OF HEATER CONTACT
BLOCKS. CHECK HIGH LIMIT SWITCH, BYPASS OR
TEST OHMS.
CHECK CONTACTOR FUSES, EACH HEATER HAS
THREE FUSES FOR LOW HEAT & THREE FUSES
FOR HIGH HEAT .

TURN UNIT ON, ENGAGE BLOWER SWITCH, FUSES
BLOW FOR VFD.

CHECK CONNECTIONS IN VFD, THREE BLACK WIRES FOR
POWER SUPPLY & THREE BLACK WIRES FOR MOTOR
OUTPUT. IF ALL CONNECTIONS LOOK GOOD, TRY
DISCONNECTING MOTOR AND TRY AGAIN. IF FUSES BLOW
AGAIN, ISSUE WITH VFD. IF FUSES DO NOT BLOW CHECK
MOTOR & BLOWER WHEEL

BLOWER ENGAGED, HEAT SWITCHES ADJUST
AIR FLOW, BUT HEAT ELEMENT DOES NOT
COME ON

CHECK CONTACTOR FUSES. CHECK CONTACT BLOCK
BEHIND HEATER SWITCH (RED WIRE) PERFORM OHM
RESISTANCE TEST. BYPASS HIGH LIMIT & OR AIR
PRESSURE SWITCH. IF ELEMENT STILL DOES NOT
ENGAGE, RUN JUMPER WIRE FROM TB3 TO TB10, IF
ELEMENT WORKS, PROBLEM WITH ONE OF THE
RELAYS. R1 (RELAY) IS FOR THE AIR PRESSURE
SWITCH & R2 (RELAY) IS FOR THE HIGH LIMIT SWITCH.

IF NEED TO INCREASE AIRFLOW & WHEN YOU TRY
TO ADJUST THE VFD ORIGINAL HZ SETTINGS,
FLASHES THE CODE: “cE” IS DISPLAYED ON
SCREEN

EPM HAS ISSUES WITH PARAMETER SETTINGS, ENTER
PASSWORD INTO VFD, GO TO P199 AND CHANGE SETTING
TO “5” FROM “0” THEN TRY TO MAKE SPEED CHANGES.
THAT WILL CONVERT EPM DATA TO CURRENT VERSION

BLOWER ENGAGED, BUT ONLY
ONE HEAT SWITCH WORKS

IS THE VFD ADJUSTING AIRFLOW? IF
SO, THE COMMAND CONTACT BLOCK
FUNCTION WORKS CORRECTLY.
CHECK CONTACT BLOCKS ON BACK OF
SWITCH, PERFORM OHM RESISTANCE
TEST.
CHECK FUSES TO THE CONTACTOR
THAT IS NOT WORKING PROPERLY.
DO OHM TEST OF ELEMENT (EACH SIDE
TEST SEPARATE FLE-60 (20KW, 40KW)
FLE-150 (60KW, 90KW) PLEASE SEE
CHART BELOW FOR READINGS:

TEST OHM READING

FLE-60 (20KW BANK) 22.5-23 OHMS

FLE-60 (40KW BANK) 9-11 OHMS

OHM READING MAY VARY, WHAT MATTERS IS THAT EACH BANK IS

SIMULAR BETWEEN THE THREE PHASES, IF OHMS ARE NOT SIMULAR,

INSPECT OF HEATING ELEMENT MAY BE REQUIRED