FloAire Modular Packaged Unit User Manual

FOR YOUR SAFETY

Modular Packaged Unit

Installation, Operation and Maintenance Manual

Modular Packaged Cooling Unit

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RECEIVING AND INSPECTION

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.

If you smell gas:

1. Open windows.

2. Do not touch electrical switches.

3. Extinguish any open flames.

4. Immediately call your gas supplier.

Warning!!

while hoisting this unit. All lifting lugs must be utilized while hoisting. Manufacturer is
not liable for any damage or injuries resulting from failure to do so.

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.

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
prior to working on heater.

Spreader Bar with length matching that of this entire unit Must be used

. 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.

July 2014 Rev. 12

TABLE OF CONTENTS

WARRANTY .................................................................................................................................................. 3

INSTALLATION ............................................................................................................................................. 4

Mechanical ................................................................................................................................................ 4

Site Preparation .................................................................................................................................... 4

Assembly .............................................................................................................................................. 4

Curb and Ductwork ............................................................................................................................... 4

Optional Moisture Eliminator Panel ...................................................................................................... 5

Typical Roof Mount Installation ............................................................................................................ 6

Typical Roof Mount Installation with Exhaust Fan ............................................................................... 6

Plumbing Connections ......................................................................................................................... 7

Typical Cooling Coil Drain Trap ............................................................................................................ 7

Gas ........................................................................................................................................................... 7

Electrical ................................................................................................................................................... 7

Copper Wire Ampacity ......................................................................................................................... 8

MUA/Condenser Fan to Building Wiring Connection ........................................................................... 9

OPERATION ............................................................................................................................................... 10

Start Up ................................................................................................................................................... 10

Special Tools Required ...................................................................................................................... 10

Start Up Procedure ............................................................................................................................. 10

Checking the Refrigerant Charge ....................................................................................................... 11

Superheat and Adjusting TXVs .......................................................................................................... 12

Checking Heating Mode for Units with Heat Pumps .......................................................................... 13

Sequence of Operation-Cooling with Direct, Indirect, or Electric Heat ................................................... 14

Sequence of Operation-Reheat .......................................................................................................... 15

Sequence of Operation-Liquid Bypass ............................................................................................... 15

Sequence of Operation-Cooling Only or Heat Pump.............................................................................. 15

Board Menu ............................................................................................................................................ 18

Troubleshooting Chart ............................................................................................................................ 20

MAINTENANCE .......................................................................................................................................... 21

General Maintenance ............................................................................................................................. 21

2 weeks after startup .............................................................................................................................. 21

Every 3 months ....................................................................................................................................... 21

Yearly ...................................................................................................................................................... 22

Start-Up and Maintenance Documentation ............................................................................................ 23

Job Information ................................................................................................................................... 23

Unit Information .................................................................................................................................. 23

Maintenance Record .......................................................................................................................... 24

Factory Service Department ............................................................................................................... 24

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.

3

INSTALLATION

CLEARANCES

It is imperative that this unit is installed and operated with the designed airflow, gas, 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 OR
MOTOR SHAFT, OR BEARINGS – USE ALL LIFTING LUGS PROVIDED WITH A
SPREADER BAR OR SLINGS UNDER THE UNIT – USE CARE NOT TO DAMAGE
EXPOSED REFRIGERATIION LINES.

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 unit inlet shall be
located in accordance with the applicable building code provisions
for ventilation air.

The top, back and front
surfaces of this unit may
not be installed less than 6”
from combustible materials.
The base may be installed
on combustible surfaces.
Allow 24” minimum service
clearance on both sides of
this unit. Do not enclose
top of condensers blocking
airflow.

Assembly

Intakes and curbs are shipped unassembled. Upon unit arrival, follow the following procedure to
assemble the intake to the heater:

1. Apply silicone or weatherproof gasket on the backside of the flanges of the intake hood or v-bank
intake.

2. Screw the flanges of the intake hood or v-bank to the unit with the supplied sheet metal screws.
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 main unit with the bolts provided. Place caulk on the outside of the screws
to prevent water leaks.

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. 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 depending upon curb installation and roofing
material. Check all fasteners for tightness. The diagrams below show different mechanical installation
configurations.

4

Optional Moisture Eliminator Panel

If the unit is equipped with an optional moisture eliminator panel, the maximum face velocity of the coil
may be increased to 650 FPM. Moisture eliminator panels require minimal maintenance. Visual
inspection is recommended periodically. Scale or clogging will impair performance. If scale or clogging
occurs, remove the panel and flush with steam or water. Flushing should not have sufficient force to
dislodge the media from the panel. Scale removal may require a vinegar or detergent application
followed by rinsing.

5

Typical Roof Mount Installation

Typical Roof Mount Installation with Exhaust Fan

6

Plumbing Connections

WARNING!!

There is one field plumbing connection required for proper DX coil operation. This is the drain pan
located under the DX coil. Depending on the size of the unit, the coil can generate 5 gallons of water per
hour. It is imperative that the plumbing be sized accordingly. Also, it’s recommended that all plumbing
connections be sealed with Teflon tape or pipe dope.

Only 1” diameter PVC Pipe and low profile couplings should be used. Additionally, the top horizontal
length on the P-Trap should be a minimum of 12”. No unions should be used. Add a clean out as shown
in the picture below.

The P-Trap drain should be attached to the end of the drain pipe on the side of the unit. The trap is
important for two reasons. First, it can be piped to drain in the most convenient area. Second, it keeps
air from being drawn through the drain hole in the side of the pan, impeding drainage.

Typical Cooling Coil Drain Trap

Gas

Refer to the Make-up air (MUA) manual that shipped with this unit for gas installation details.

Electrical

Before connecting power to this unit, read and understand the
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 ordinances and the National Electric Code,
ANSI/NFPA70. Be sure the voltage and phase of the power
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.

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.

7

1. Always disconnect power before working on or near
this unit. Lock and tag the disconnect switch or breaker
to prevent accidental power up.

2. This unit contains 2 or 3 disconnect switches and
multiple wiring connections. 1 disconnect is for the mua
blower. The second disconnect is used for units with 2
condensers. A third disconnect is added for units with 3
condensers. An electrical drop containing the motor
power wiring and a separate
drop containing condenser
power is shipped with every
fan. The electrical drops
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. 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. 3 phase condensers
have circuit boards that protect the compressor from running backwards. The board (located
under the condenser wiring panel) will produce a fault light if the 3 phase input needs to be
reversed to that condenser.

5. Units shipped with an optional remote panel have three 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 either be shielded cable or be run
in a separate conduit.

6. Before connecting unit to the building power source, verify power line wiring is de-energized.

7. Secure the power cables to prevent contact with sharp objects.

8. Do not kink power cable and never allow the cable to come in contact with oil, grease, hot
surfaces or chemicals.

9. 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.

10. If any of the original wire supplied with the heater must be replaced, it must be replaced with type
THHN wire or equivalent.

Copper Wire Ampacity

Wire Size AWG Maximum Amps

14 15
12 20
10 30

8 50
6 65
4 85

8