FloAire FAV User Manual
Installation & Operation
Guide
Industrial
Non
Re-circulating
Direct
-
Fired Heaters
Horizontal / Vertical and Single / Twin Blowers
.
FOR YOUR SAFETY
If You smell gas:
1. Open windows
2. Don’t touch electrical switches
3. Extinguish any open flames
4. Immediately call your gas supplier
WARNING!!
FOR YOUR SAFETY
The use and storage of gasoline or
other flammable vapors and liquids in
open containers in the vicinity of this
appliance is hazardous!
Improper installation, adjustment, alteration, service or maintenance can cause
property damage, injury or death. Read the installation, operating and
maintenance instructions thoroughly before installing or servicing this equipment
ALWAYS disconnect power and gas before working on heater.
RECEIVING AND INSPECTION
Upon receiving unit, check for any interior or 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.
NOTE TO INSTALLER
Please complete and return the
Start-UP Checklist on the back of this
manual to validate warranty
NOTE TO INSTALLER
This manual should be reviewed with
the customer and left with the
equipment user
Revision 12 – 11.19.2013
2
TABLE OF CONTENTS
WARRANTY ............................................................................................................................... 4
INSTALLATION ........................................................................................................................... 4
Gas ........................................................................................................................................... 11
Electrical ............................................................................................................................... 12
Gas Connection Diagram .................................................................................................. 12
Copper Wire Ampacity ...................................................................................................... 12
SEQUENCE OF OPERATIONS ................................................................................................ 13
Standard Sequence of Operation .......................................................................................... 13
Additional Sequence of Operation – All VFD Motor Control.................................................... 14
VFD Preset Speeds .............................................................................................................. 14
START-UP PROCEDURE ......................................................................................................... 15
PROFILE ADJUSTMENTS ........................................................................................................ 21
VFD Drive Installation & Programming Instructions .................................................................... 22
OTHER UNIT COMPONENTS .................................................................................................. 24
Flame Safety Control ........................................................................................................ 24
High Temperature Limit ..................................................................................................... 24
Electric Cabinet Heater ..................................................................................................... 24
DC Flame Signal ............................................................................................................... 24
TROUBLESHOOTING .............................................................................................................. 26
MAINTENANCE ........................................................................................................................ 38
Burner Orifice Drill Size .................................................................................................... 39
START-UP CHECKLIST ........................................................................................................... 40
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:
• the equipment is not installed by a qualified installer per the manufacturer’s installation
instructions shipped with the product
• the equipment is not installed in accordance with federal, state and local codes and
regulations
• the equipment is misused or neglected
• the equipment is not operated within its published capacity
• the invoice is not paid within the terms of the sales agreement
• the Start-Up Checklist has not been filled in by a qualified technician and returned to the
Factory Service Department
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.
NOTE TO INSTALLER
Please complete and return the
Start-UP Checklist on the back of this manual to validate warranty
INSTALLATION
It is imperative that this unit is installed and operated with the designed airflow, gas, and electrical
supply in accordance with this manual. Any variance to these instructions may cause the unit to not
perform to specifications and may cause severe damage to the unit or jobsite. Please call the service
department at 866-784-6900 for assistance on warranty issues and technical support.
Inspection on Arrival
1. Inspect unit on delivery
2. Photograph any visible damage
3. Report any damage to the delivery carrier
4. Request a written inspection report from the
Claims Inspector to substantiate claim
5. File claims with delivery carrier
Unit Location
1. Do not locate any gas-fired equipment near
corrosive or explosive vapors such as
chlorinated or acid vapors
2. Avoid overhead power lines, or other utility
access to prevent accidental contact or
damage.
3. Provide clearance around installation site to
safely rig and lift the equipment into its final
6. Check unit’s rating plate to verify proper
electric and fuel type to meet job
requirements
7. Compare unit received with description of
product ordered
position onto adequate supports. Refer to
the manufacturer’s estimated weights.
4. Consider general service and installation
space when locating the unit.
5. Locate the unit close to the space it will
serve to reduce long, twisted duct runs.
6. Do not allow air intake to face prevailing
winds. Air flow switch may trip in high winds.
4
7. Situate the unit above ground or at roof level
high enough to prevent precipitation from
being drawn into its inlet.
8. The inlet must also be located at least 10
feet away from any exhaust vents.
9. The heater inlet must be located in
accordance with the applicable building
code provisions for ventilation air.
10. All air to the heater must be ducted from the
outdoors.
11. Recirculation of room air is not permitted. If
in doubt regarding the application, consult
the manufacturer.
12. The unit must have adequate structural
support or the equipment or building could
be damaged.
13. Do not alter or otherwise restrict combustion
or ventilation openings.
14. Direct-fired units should not be installed
downstream from cooling systems which
use refrigerants for cooling.
COMBUSTABLE
CLEARANCES
The top, back, and front surfaces
of this heater may not be installed
less than 6 inches from
combustible materials. The heater
base may be installed on
combustible surfaces.
SERVICE CLEARANCES
Allow 24 inches or greater
minimum service clearance on all
sides of this heater. Allow 48
inches or greater on the vestibule
and blower door side.
Rigging
1. Horizontal units are supplied with four lifting lugs on the bottom corners of the casing.
2. Vertical units are supplied with four lifting lugs at the top corners of the casings.
3. Lift the unit and accessories separately, attach the accessories to the unit once the unit is in place.
4. The following diagrams represent the proper methods for lifting the unit and accessories.
5. Always use spreader bars to prevent damage to the unit casing.
5
FIGURE 1: SIZE 10, 12, 15, & 18 FIGURE 2: NO SPREADER BARS
FIGURE 3: WITH SPREADER BARS FIGURE 4: ACCESSORIES
CAUTION!!
These are unbalanced loads
Lift equipment gently
Do not jerk
Spreader bars must be used and should extend
past the edges of the equipment to avoid damage
to the casing. Not using spreader bars may cause
WARNING!!
WARNING!!
damage to the casing
Damage will result if the equipment is raised by the intake hood, blower, motor shaft, or bearings
Use the provided lifting eyes and brackets on the unit
Curbs
The unit must have adequate structural support or the equipment or building could be damaged. The curb
and unit must be leveled or the unit may leak or be damaged. Use gasket and caulk between the curb
and unit. Use shims if necessary to level the unit. Screw or weld the unit’s base to the curb to avoid
damage to the equipment.
6
WARNING!!
The unit must have adequate structural
support or the equipment or building
could be damaged.
WARNING!!
Screw or weld the unit’s base to the curb
to avoid damage to the equipment.
WARNING!!
The curb and unit must be leveled or the
unit may leak or be damaged.
Accessories
Intake and discharge accessories are shipped loose and unassembled. When attaching the accessories
to the unit use gasket, caulk, and #10 sheet metal screws on all seams. All accessories must be level.
WARNING!!
Use gasket, caulk, and #10 sheet metal screws on
all component intersections. Leaking may result if
the intersections are not completed properly.
The accessories must be level and support legs
attached to the hood and solid part of the roof.
Equipment that is not level or properly supported
WARNING!!
may leak or be damaged.
Split Units
1. Apply weather-proof gasket to the seam of the vertical or horizontal unit
2. Use provided fasteners to secure the seam of the unit using the provided pre-punched holes
a. Horizontal units internal channels and a formed frame
b. Vertical units have angles on the outside of the casing
3. Apply silicone to the outside edge of the seam
4. Field wire the discharge air sensor using a minimum 22 gauge wire
5. Mount the high temperature limit bulb to the blower housing
6. Mount the (optional) freeze control sensor to the blower housing
7
FIGURE 1: HORIZONTAL SPLIT ASSEMBLY FIGURE 2: VERTICAL SPLIT ASSEMBLY
8
Shipped Loose Intake or Discharge Dampers
In some cases an intake or discharge damper may be shipped loose. This may be requested by the
customer or can be required because of larger units shipping size restrictions. Follow these instructions to
attach and wire the shipped loose damper. Factory mounted dampers may be attached on the unit and
will not require assembly or field wiring.
1. Attach the damper to the intake or discharge using gasket, caulk, and #10
sheet metal screws
2. Field wire the damper using the as built wiring schematic for the specific unit. Wiring may be different
depending on the model and options selected.
3. Refer to the factory supplied wiring print to verify the field wiring terminals.
Ductwork
This fan was specified for a specific CFM and static pressure. The ductwork attached to this unit will
significantly affect the airflow performance.
WARNING!!
• Flexible ductwork and square elbows should not be used
• Transitions and turns in ductwork near the fan outlet will cause system effect and will drastically
increase the static pressure and reduce airflow
• The Ductwork Sizing Chart shows the minimum fan outlet duct sizes and straight lengths
recommended for optimal fan performance
• Units with twin blower must have a common discharge plenum
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. It is recommended an outdoor unit be installed on
a curb and/or rail elevated so intake is not less than 20” above any surface. Be sure the duct connection
and fan outlet are properly aligned and sealed.
Adequate building relief is necessary in order to prevent over-pressurizing the building when the heater is
operating at capacity. This can be accomplished by establishing properly-sized relief openings, an
interlocked exhaust system, or both.
Heaters installed with intake ductwork must be purged to replace at least four air changes of the volume
of the intake duct.
In order to avoid hazards to other fuel-burning equipment in the building (i.e., when the heater is providing
make-up air to a boiler room), the unit should be interlocked to open inlet air dampers or other such
devices.
On outdoor installations, it is recommended that the discharge duct be insulated to prevent condensation
during the “OFF” cycle in cold weather.
Units being installed in airplane hangars should be installed in accordance with the Standard for Aircraft
Hangars, ANSI/NFPA 409. Units being installed in public garages should be installed in accordance
with the Standard for Parking Structures, ANSI/NFPA 88A, or the Standard for Repair Garages,
ANSI/NFPA 88B, and with CAN/CGA B149 Installation Codes.
Flexible connectors should be employed on all ductwork connections. Vibration isolators are optional and
can be supplied in the loose parts package.
Ductwork Sizing Chart Single Blower
Blower Size
Duct Size
(Inches)
Duct Length
(Inches)
Ductwork Sizing Chart Dual Blowers
Blower Size
Duct Size
(Inches)
Duct Length
(Inches)
9
10 14 x 14 30
12 16 x 16 36
15 20 x 20 45
18 24 x 24 54
20 26 x 26 60
22 30 x 30 66
25 32 x 32 75
27 36 x 36 81
30 38 x 38 90
33 44 x 44 99
36 44 x 44 108
Installation Examples
222 77 x 28 66
225 88 x 32 75
227 96 x 36 81
230 104 x 38 90
233 116 x 44 99
236 122 x 44 108
WARNING!!
Failure to undersize ductwork size or length
may cause system affect and reduce the
performance of the equipment.
Using the unit to support the ductwork may
cause damage to the units casing.
Figure 1: Horizontal Roof Top Installation
Down discharge AMU reduces ductwork
Hood weight supported by support legs
Union, regulator, and shut-off
Roof curb supports unit
Intake facing away from prevailing winds
Figure 2: Vertical Outdoor Ground Installation
Side discharge AMU reduces ductwork
Support stand on concrete pad
Union, regulator, and shut-off
Filter section inside support stand
Ease of serviceability on ground
10
Gas
Gas piping must be installed to conform with local building codes, or in the absence of local codes, the
National Fuel Gas Code, ANSI Z223.1 (NFPA 54) – latest edition. In Canada, gas piping must be
installed in accordance with CAN/CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for propane
units.
WARNING
Inlet gas pressure must not exceed pressure
indicated on name plate.
Refer to the heater rating plate for
determining the minimum gas supply
pressure for obtaining the maximum gas
capacity for which this heater is specified.
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. Piping to the unit should conform to local
and national requirements for type and
volume of gas handled, and pressure drop
allowed in the line. Refer to the Gas
Engineer’s Handbook for gas line capacities.
3. The incoming pipe near the heater should
be sized to match the connection on the
outside of the unit. Unit inlet sizes are shown
in the table to the right. Avoid multiple taps
in the gas supply so the unit has a steady
supply of gas at all times.
4. Install a ground joint union with brass seat
and a manual shut-off valve external to the
unit casing, as shown below, adjacent to the
unit for emergency shut-off and easy
servicing of controls.
5. Provide a sediment trap, as shown below,
before each unit and where low spots in the
pipe line cannot be avoided.
6. Blow out the gas line to remove debris
before making connections. Before starting
the unit, purge line to remove air. Purge air
from gas lines according to ANSI Z223.1latest edition “National Fuel Gas Code,” or in
Canada: CAN/CGA-B149.
7. All field gas piping must be pressure/leak
tested prior to operating the unit. Use a
soap solution or equivalent for leak testing.
The heater and its individual shut-off valve
must be disconnected from the gas supply
piping system during any pressure testing of
that system at test pressures in excess of ½
PSI. During any pressure testing of the gas
supply piping system at test pressures equal
to or less than ½ PSI, the heater must be
isolated from the gas supply piping system
and its individual manual shutoff valve
closed.
8. This unit requires the gas pressure to be
within the unit’s minimum and maximum gas
pressure ratings. If the pressure is greater
than the maximum, the internal valve
components will be damaged. If the
pressure is below the minimum, the heater
will not perform to specifications.
9. If installing on a paint booth application, a
manual shutoff should be located for access
in case of a fire or explosion at the heater.
Gas Connection Sizes
BTU Input
158,000
275,000
549,999
1,099,999
1,374,999
1,649,999
1,924,999
2,474,999
2,749,999
3,574,999
4,124,999
5,224,999
5,774,999
7,974,999
8,524,999
9,624,999
11,274,999
11,824,999
12,924,999
16,847,999
Gas Pressure (Inches W.C. & PSI)
7” – 14” 15” – 1# 1# - 5#
½ ½ ½
¾ ½ ½
¾ ¾ ¾
1 ¾ ¾
1 ¼ ¾ ¾
1 ½ 1 1
2 1 1
2 1 ¼ 1
2 1 ½ 1
2 2 1 ¼
2 2 1 ½
2 ½ 2 2
2 ½ 2 2
2 2
2 ½ 2
2 ½ 2
2 ½ 2
3 2
3 2 ½
3
11
Gas Connection Diagram
Electrical
Before connecting power to the heater, read and understand this entire section. Wiring diagrams are
furnished with each fan by the factory, and are attached to the door of the unit.
WARNING!!
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.
Electrical wiring must be done in accordance with local ordinances and the National Electric Code,
ANSI/NFPA70. Be sure the voltage and phase of the power supply and the wire amperage capacity
conform to those listed on 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.”
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. A dedicated circuit should supply the units electrical disconnect with circuit protection, according to
the National Electric Code.
3. 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.
4. Units shipped with an optional remote panel have two electrical circuit. It is important to run the motor
wires in a conduit separate from the remote control wiring. The DC wires from the unit temperature
controller, located in the control drop, should be either in shielded cable or run in a separate conduit.
5. Before connecting the heater to the building power source, verify the power line wiring is deenergized.
6. Secure the power cables to prevent contact with sharp objects.
7. Do not kink power cable and never allow the cable to come in contact
with oil, grease, hot surfaces or chemicals.
8. 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.
12
Copper Wire Ampacity
Wire Size AWG Maximum Amps
14 20
12 25
10 30
8 40
6 55
4 70
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