Air King AK50S User manual

IMPORTANT INSTRUCTIONS -
OPERATING MANUAL
READ AND SAVE THESE INSTRUCTIONS
READ CAREFULLY BEFORE ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE OR MAINTAIN
THE PRODUCT DESCRIBED. PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY
INFORMATION. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL
INJURY AND/OR PROPERTY DAMAGE!
RETAIN INSTRUCTIONS FOR FUTURE REFERENCE.
GENERAL SAFETY INFORMATION
When using electrical appliances, basic precautions should
always be followed to reduce the risk of fire, electric shock and
injury to person, including the following:
SAVE THESE INSTRUCTIONS
WARNING:TO REDUCE THE RISK
OF FIRE, ELECTRIC SHOCK AND INJURY TO
PERSON, OBSERVE THE FOLLOWING:
a) Use this unit only in the manner intended by the manufacturer. If you have
questions, contact the manufacturer.
b) Before servicing or cleaning the unit, switch power off at service
panel and lock the service disconnecting means to prevent power
from being switched on accidentally. When the service disconnecting
means cannot be locked, securely fasten a prominent warning
device, such as a tag, to the service panel.
WARNING:TO REDUCE THE RISK
OF FIRE, ELECTRIC SHOCK AND INJURY TO
PERSON, OBSERVE THE FOLLOWING:
a) Installation work and electrical wiring must be done by qualified
person(s) in accordance with all applicable codes and standards,
including fire-related construction.
b) Sufficient air is needed for proper combustion and exhausting of
gases through the flue (chimney) of fuel burning equipment to prevent
back drafting. Follow the heating equipment manufacturer’s guideline
and safety standards such as those published by the National Fire
Protection Association (NFPA) and the American Society for Heating,
Refrigeration, and Air Conditioning Engineers (ASHRAE), and the local
code authorities.
c) When cutting or drilling into wall or ceiling, do not damage electrical
wiring and other hidden utilities.
CAUTION:FOR GENERAL VENTILATING USE ONLY.
DO NOT USE TO EXHAUST HAZARDOUS OR EXPLOSIVE
MATERIALS AND VAPORS.
d) Ducted fans must always be vented to the outdoors.
e) This unit must be grounded.
f) To avoid motor bearing damage and noisy and/or unbalanced impellers,
keep drywall spray, construction dust, etc. off power unit.
g) Read all instructions before installing or using exhaust fan.
WARNING:TO REDUCE THE RISK OF FIRE,
ELECTRIC SHOCK, DO NOT USE THIS FAN WITH
ANY SOLID-STATE SPEED CONTROL DEVICE.
a) If this unit is to be installed over a tub or shower, it must be
marked as appropriate for the application and be connected to a
GFCI (Ground Fault Circuit Interrupter) – protected branch circuit.
WARNING:DO NOT USE IN KITCHENS.
WARNING: THE DUCTING FROM THIS FAN TO THE
OUTSIDE OF THE BUILDING HAS A STRONG EFFECT
ON THE AIR FLOW, NOISE AND ENERGY USE OF THE FAN. USE
THE SHORTEST, STRAIGHTEST DUCT ROUTING POSSIBLE FOR
BEST PERFORMANCE, AND AVOID INSTALLING THE FAN WITH
SMALLER DUCTS THAN RECOMMENDED. INSULATION AROUND
THE DUCTS CAN REDUCE ENERGY LOSS AND INHIBIT MOLD
GROWTH. FANS INSTALLED WITH EXISTING DUCTS MAY NOT
ACHIEVE THEIR RATED AIRFLOW.
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A210952009 Rev. Q 4-16 1 of 8
Exhaust Fan
Models: AK50S, AK80LS-1, AK80, AK90,
AK110PN, AK110, AK130

INSTALLATION INSTRUCTIONS
CAUTION: MAKE SURE POWER IS SWITCHED OFF AT
SERVICE PANEL BEFORE STARTING INSTALLATION.
SECTION 1
Preparing the Exhaust Fan
1. Unpack fan from the carton and confirm that all pieces are present. In addition to the
exhaust fan you should have:
1 - Grill
1 - Damper Assembly (attached)
4 - Mounting Rails
1 - Instruction/Safety Sheet
2. Choose the location for your fan. To ensure the best air and sound performance, it
is recommended that the length of ducting and the number of elbows be kept to a
minimum, the radius of each elbow be as large as
possible for the installation, and that insulated hard
ducting be used. This fan will require at least 8" of
clearance in the ceiling or wall, and will mount through
drywall up to 3/4" thick. The fan mounts between 16”
or 24” on center joists using the 4 provided mounting
rails.
3. Select the most convenient electrical knockout and
remove using a straight-blade screw driver (Figure 1).
4. No additional vibration deadening materials are needed
for this fan.
SECTION 2
New Construction
1. Install the rails into the mounting channel on the housing. Center the mounting channel in
the slots on the housing, then from inside the housing tighten the mounting channel screws
so the channel is securely in place. Position the housing next to the joist. Line up housing so
that it will be flush with the finished ceiling. Secure the ends of the rails with screws or nails
(not included) to the joists and slide the housing into the final position (Figure 2).
SECTION 3
Existing Construction
1. Set housing in position between the joist and trace an outline onto the ceiling material
(Figure 3). Set housing aside and cut opening, being careful not to cut or damage any
electrical or other hidden utilities. Install the rails into the mounting channel on the
housing. Center the mounting channel in the slots on the housing, then from inside
the housing tighten the mounting channel screws so the channel is securely in place.
Position the housing in the previously cut hole so that it is flush with the finished ceiling.
Secure the ends of the rails to the joists (Figure 2).
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A210952009 Rev. Q 4-16 2 of 8
SECTION 4
Ducting
NOTE: 4" OR LARGER RIGID DUCT IS RECOMMENDED FOR BEST PERFORMANCE.
CAUTION: ALL DUCTING MUST COMPLY WITH LOCAL AND
NATIONAL BUILDING CODES.
NOTE: The ducting from this fan to the outside of the building has a strong effect on the air
flow, noise and energy use of the fan. Use the shortest, straightest duct routing possible
for best performance, and avoid installing the fan with smaller ducts than recommended.
Insulation around the ducts can reduce energy loss and inhibit mold growth. Fans installed
with existing ducts may not achieve their rated air flow.
1. Connect the ducting to the fan’s duct collar (Figure 4). Secure in place using tape
or screw clamp. Always duct the fan to the outside through a wall or roof cap. It is
recommended that low restriction termination fittings be used.
2. Ensure duct joints and exterior penetrations are sealed with caulk or other similar
material to create an air-tight path to minimize building heat loss or gain and to reduce
the potential for condensation. Place/wrap insulation around duct and/or fan in order to
minimize possible condensation buildup within the duct, as well as building heat loss or
gain (Figure 5).
SECTION 5
Wiring
CAUTION: MAKE SURE POWER IS SWITCHED OFF AT
SERVICE PANEL BEFORE STARTING INSTALLATION.
CAUTION: ALL ELECTRICAL CONNECTIONS MUST BE MADE
IN ACCORDANCE WITH LOCAL CODES, ORDINANCES, OR NATIONAL
ELECTRICAL CODE. IF YOU ARE UNFAMILIAR WITH METHODS OF INSTALLING ELECTRICAL
WIRING, SECURE THE SERVICES OF A QUALIFIED ELECTRICIAN.
NOTE: This unit may include a side access panel for wiring that does not require the removal of
the fan’s blower assembly. If you choose to wire the unit from the inside, you will need to remove
the blower assembly and internal wiring compartment. Both methods are equally effective.
1a. External Wire Compartment (Not included with all models): Remove the wire
compartment cover screw and place cover in a secure place (Figure 6).
Figure 1
Figure 2
Housing
Joist
Mounting Rails
Ducting
Duct
Collar
Figure 4
Figure 5
Insulation*
(place around and
over Fan Housing
Fan Housing
Power Cable*
Seal gaps
around Housing
Round
Duct*
Seal duct joints
with tape
Round
Elbows* Wall Cap*
Roof Cap*
(with built-in
damper)
Keep duct
runs short
*Purchase separately
or
Figure 3
Joist

1b. Internal Wire Compartment: Remove the screw holding the venturi in place. Lift the
venturi up and at an angle to slide it out of the housing (Figure 7). Remove the wire
compartment cover screw and place the cover in a secure place (Figure 8).
NOTE: If the fan motor plug is
connected to the fan housing
receptacle, unplug so the blower
assembly can be completely removed.
2. Run wiring from an approved wall switch carrying the appropriate rating. One neutral
(white), one ground (green or bare copper), and one hot (black lead connected to the switch).
Secure the electrical wires to the housing with an approved electrical connector. Make sure
you leave enough wiring in the box to make the connection to the fan’s receptacle.
3. From where you have chosen to access the fan’s junction box, connect the White wire
from the house to the White wire from the fan’s receptacle. Connect the Black wire from
the wall switch to the Black wire from the fan’s receptacle. Connect the ground wire
from the house to the Green wire from the fan’s receptacle (Figure 9). Use approved
methods for all connections.
NOTE: The fan’s receptacle wires might need to be pulled outside compartment for connection.
Only pull the three loose wires outside of compartment. Additional wires will be present.
4. Carefully tuck wire back inside wire compartment and replace wire compartment cover
securing with the screw that was removed earlier.
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A210952009 Rev. Q 4-16 3 of 8
SECTION 6
Completing the Installation
1. Use a sealant appropriate for contact with the building materials present and for the
temperature requirements of the installation to prevent air leakage from unconditioned
spaces is recommended. If gaps between unit housing and ceiling are great, additional
material (backing rod, ceiling material) may be required.
NOTE: This fan is rated for direct insulation contact (Type IC) and it is recommended that this fan
be completely covered by insulation in order to reduce heat loss or gain to unconditioned space.
2. If the fan’s blower assembly was removed during the wiring process, reinstall the
blower by reversing the directions in Section 5 (Wiring), Step 1b.
3. Plug the fan’s quick connect motor cord into the receptacle. This cord will only fit one
way into the receptacle (Figure 10).
4. Install the grill by squeezing the two ends of the springs together and installing them up
into the slots on the fan’s housing. Push the grill up into position (Figure 11).
5. Restore power and test your installation.
SECTION 7
Use and Care
CAUTION: MAKE SURE POWER IS SWITCHED OFF AT
SERVICE PANEL BEFORE SERVICING THE UNIT.
1. Cleaning the Grill: Remove grill and use a mild detergent, such as dishwashing liquid,
and dry with a soft cloth. NEVER USE ANY ABRASIVE PADS OR SCOURING POWDERS.
Completely dry grill before reinstalling. Refer to instructions in Section 6 Finishing the
Installation, to reinstall grill.
2. Cleaning the Fan Assembly: Wipe all parts with a dry cloth or gently vacuum the fan.
NEVER IMMERSE ELECTRICAL PARTS IN WATER.
CALIFORNIA RESIDENTS ONLY:
WARNING: THIS PRODUCT CAN EXPOSE YOU TO A CHEMICAL [OR
CHEMICALS] KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER.
WARNING: THIS PRODUCT CAN EXPOSE YOU TO A CHEMICAL
[OR CHEMICALS] KNOWN TO THE STATE OF CALIFORNIA TO CAUSE
REPRODUCTIVE TOXICITY.
Figure 6
Screw
Wire
Compartment
Cover
Figure 9
Supply from
house
Ground White
Hot (Black)
Figure 8
Screw Wire
Compartment
Cover
Plug
Figure 7
Venturi
Screw
Figure 11
Figure 10

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A210952009 Rev. Q 4-16 4 of 8
Installer: Installation Date:
Place of Purchase: Model Number:
LIMITED WARRANTY
WHAT THIS WARRANTY COVERS: This product is warranted against defects in workmanship and/or materials.
HOW LONG THIS WARRANTY LASTS: This warranty extends only to the original purchaser of the product and lasts for five (5) years from the date of original purchase
or until the original purchaser of the product sells or transfers the product, whichever first occurs.
WHAT AIR KING WILL DO: During the warranty period, Air King will, at its sole option, repair or replace any part or parts that prove to be defective or replace the whole
product with the same or comparable model.
WHAT THIS WARRANTY DOES NOT COVER: This warranty does not apply if the product was damaged or failed because of accident, improper handling or operation,
shipping damage, abuse, misuse, unauthorized repairs made or attempted. This warranty does not cover shipping costs for the return of products to Air King for repair or
replacement. Air King will pay return shipping charges from Air King following warranty repairs or replacement
ANY AND ALL WARRANTIES, EXPRESSED OR IMPLIED (INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY), LAST ONE YEAR
FROM THE DATE OF ORIGINAL PURCHASE OR UNTIL THE ORIGINAL PURCHASER OF THE PRODUCT SELLS OR TRANSFERS THE PRODUCT, WHICHEVER FIRST
OCCURS AND IN NO EVENT SHALL AIR KING’S LIABILITY UNDER ANY EXPRESS OR IMPLIED WARRANTY INCLUDE (I) INCIDENTAL OR CONSEQUENTIAL DAMAGES
FROM ANY CAUSE WHATSOEVER, OR (II) REPLACMENT OR REPAIR OF ANY HOUSE FUSES, CIRCUIT BREAKERS OR RECEPTACLES. NOTWITHSTANDING ANYTHING TO
THE CONTRARY, IN NO EVENT SHALL AIR KING’S LIABILITY UNDER ANY EXPRESS OR IMPLIED WARRANTY EXCEED THE PURCHASE PRICE OF THE PRODUCT
AND ANY SUCH LIABILITY SHALL TERMINATE UPON THE EXPIRATION OF THE WARRANTY PERIOD.
Some states and provinces do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so these
exclusions or limitations may not apply to you. This warranty gives you specific legal rights. You may also have other rights which vary from state to state and province to
province. Proof of purchase is required before a warranty claim will be accepted.
CUSTOMER SERVICE:
Toll-Free [phone]
Our Customer Service team is available to assist you with product questions, service center locations, and replacement parts. They can be reached Monday through
Friday, 8am-4pm Eastern. Please have your model number available, as well as the type and style (located on the label inside of your product).
Please do not return product to place of purchase.
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PARTS FOR DISCONTINUED, OBSOLETE AND CERTAIN OTHER PRODUCTS MAY NOT BE AVAILABLE. DUE TO SAFETY REASONS, MANY ELECTRONIC COMPONENTS
AND MOST HEATER COMPONENTS ARE NOT AVAILABLE TO CONSUMERS FOR INSTALLATION OR REPLACEMENT.
4
6
7
5
1
3
8
9
Troubleshooting Guide
Trouble Probable Cause Suggested Remedy
1. Fan does not operate when the switch is on. 1a. A fuse may be blown or a circuit tripped. 1a. Replace fuse or reset circuit breaker.
1b. Connector plug from motor is not plugged in. 1b. Turn off power to unit. Remove Grill and plug motor into receptacle
in housing. Restore power to unit.
1c. Wiring is not connected properly. 1c. Turn off power to unit. Check that all wires are connected.
1d Motor has stopped operating. 1d. Replace motor.
2. Fan is operating, but air moves slower than normal. 2. Obstruction in the exhaust ducting. 2. Check for any obstructions in the ducting. The most common are bird
nests in the roof cap or wall cap where the fan exhausts to the outside.
3. Fan is operating louder than normal 3a. Motor is loose. 3a. Turn off power to unit. Remove grill and check that all screws are fully
tightened. Restore power to unit.
3b. Fan blade is hitting housing of unit. 3b. Call your dealer for service.
# Qty. Description Replacement Part #
1 4 Mounting Rails 5S1299002
2 2 Mounting Channel 5S1202122
3 1 Collar Assembly 5S1299111
4 1 Blower Assembly - AK50S,
AK80LS-1, AK110, AK130
5S2202029
1Blower Assembly - AK80,
AK90, AK110PN
5S2202401
5 1 Wire Compartment 5S1202052
6 1 Grill 5S1202005
7 2 Grill Springs 5S1202006
8 1 External Wire Cover* 5S1202007
9 1 Motor Cap Harness Assembly
AK50S 5S9202510
AK80LS-1 5S9202516
AK80 5S9202513
AK90 5S9202519
AK110PN 5S9202514
AK110 5S2202012
AK130 5S9202507
* Not included with all models
2