Hastings AEROFLO AFX Series Manual

Installation and Service Manual
AEROFLO
AFX SERIES
HEATERS
GAS FIRING
Notice
Read These Instructions before Installation
ISAFX-1
April 2014
Supersedes March 2012

TABLE OF CONTENTS
Page
Section I. – General Information ………………………………………… 2
A. Purpose ……………………………………………………… 2
B. Shipping ……………………………………………………… 2
C. Storage……………………………………………………….. 2
D. Optional Factory Service …………………………………… 2
E. Equipment Description …………………………………….. 2
Section II. – Installation Procedure ………………………………………. 4
A. Handling the Equipment ……………………………………. 4
B. Positioning the Unit ……………………………………….. 4
C. Location of accessories …………………………………….. 6
D. Electrical connections ………………………………………. 6
E. Piping Connections …………………………………………. 6
F. Exhaust Duct Connection ………………………………….. 9
G. Combustion Air Openings 9
H. Optional Remote Control Panel Instructions……………… 10
Section III. – Pre-Start Inspection ………………………………………… 13
A. Procedure ……………………………………………………. 13
Section IV. – Start-up ………………………………………………………. 13
A. Procedure ……………………………………………………. 13
Section V. – Maintenance Schedule and Lubrication Requirements … 18
A. Maintenance Schedule ……………………………………... 18
B. Lubrication Instructions …………………………………….. 19
Section VI. – Troubleshooting ……………………………………………... 20
A. Troubleshooting Gas-Fired Units ………………………….. 20
B. General Troubleshooting Tips ……………………………... 20
1

SECTION I. – GENERAL INFORMATION
A. PURPOSE
The purpose of this manual is to present a guide for proper installation, maintenance,
and operation of Aeroflo AFX Series heaters, and to supplement, but not to replace,
the services of qualified field service personnel to supervise the initial start-up and
adjustment of the Aeroflo unit. Persons without previous experience with large
commercial and industrial equipment should not attempt the initial adjustment and
checkout procedure which is essential before such installations may be considered as
ready for operation. This manual should be made readily available to operating
personnel as an aid in trouble-shooting and proper maintenance.
B. SHIPPING
All Aeroflo units are shipped in three sections: fan section, heating section, and
discharge section. These sections have been designed to facilitate field installation.
All options and accessories are shipped mounted and wired whenever possible within
the limitations of shipping and handling. Any wired accessories which have been
disassembled for separate shipment require no additional conduit or wire for field
reassembly. All wire leads will be tagged for ease of reconnection in the field.
Shipments are made F.O.B. Hastings, Nebraska, by truck. In either case, the unit is
securely strapped, tied, and blocked to prevent shipping damage. All shipments are
checked by an inspector before they are accepted by the carrier. Parts that are
shipped unmounted are noted on the bill of lading. These parts, where feasible, are
packaged and shipped with the units. Upon receipt of shipment, all units should be
checked against the bill of lading to insure all items have been received. The units
should be checked carefully for physical damage in the presence of the carrier’s
representative. If parts are missing or damage has occurred, a claim should be filed
immediately with the carrier.
All Aeroflo units are given a complete operations test and control circuit checkout
before shipment. A copy of the flame test report, and wiring diagram is included with
each unit shipped. If correspondence with the factory is necessary, please provide the
unit model and serial number.
C. STORAGE
If equipment is not installed at time of receipt, the equipment must be stored in
a dry environment and free of rodents.
D. EQUIPMENT DESCRIPTION
The Aeroflo heater is a rugged floor-mounted industrial grade space heater that
achieves uniform building temperature, moisture control, and maximum heating
efficiency using the principle of low velocity constant air circulation to heat large air
volumes to lower temperatures. Refer to Bulletin AFX-1 for additional details.
1. Cabinet and Frame
Rugged tubular frame and all aluminized steel cabinet surfaces are painted with
heat and corrosion resistant industrial enamel. Unit includes four side return air
screens. An expanded metal, low velocity discharge plenum with either two,
three, or four sides screened is standard.
2

2. Fans
There are two heavy-duty, 10 gauge, turbine-bladed propeller fans each with a
one-piece solid shaft and self-aligning pre-lubricated ball bearings. Fixed drives
are standard on all units. A premium efficiency open dripproof ball bearing
squirrel cage induction T-frame motor is provided as standard for all voltages.
3. Burners
Standard burner is Hi-Lo-Off
Gas (G) – Power type with pilot spark ignition and main burner pilot ignition for
use with natural, manufactured, mixed, liquefied petroleum gas or liquefied
gas/air mixture. Included in the manifold are main gas electric shut-off valve with
linkage to combustion air damper, main and pilot gas pressure regulators for
maximum inlet pressure of 1 PSIG, pilot gas-air mixer and pilot solenoid valve.
Minimum standard entering gas pressure is 4 ounces.
4. Fuel and Electric Controls
Standard components for Aeroflo AFX Series heaters include a Nema 1 control
box with electronic flame safeguard system with ignition transformer, motor
starter, control transformer, high temperature limit switch, air flow switch, and a
gas electrical control system.
5. Control System
The standard control system for Hi-Lo-Off burner operation is obtained with a two-
stage thermostat that closes in sequence on a temperature drop below setpoint.
Fan operation is continuous. A detailed sequence of operation for standard gas-
fired heaters is provided later in this manual. The thermostat is factory furnished
and wired in the inlet plenum.
The optional On-Off control system is obtained with a single pole, single throw
thermostat that closes upon a temperature drop below setpoint. Fan operation is
continuous. Thermostat is factory furnished and wired in the inlet plenum.
The optional modulating control system has an On-Off thermostat as described
above plus a modulating thermostat to control a modulating butterfly fuel valve.
Fan operation is continuous. Thermostats are factory furnished and wired in the
inlet plenum.
6. Remote Control Panel (Optional)
The optional panel is furnished with a heavy duty toggle switch and three 115 volt
signal lights as depicted in Figure 5. The switch controls the blower and the
burner. The signal lights indicate supply blower operation (white light marked
“blower”), burner operation (amber light marked “heating”), and safety lockout (red
light marked “lockout”). Remote control panel lids are 16 gauge.
Wiring box dimensions are 8” x 5” x 3-1/2” deep. All wiring is 16 AWG 16/30
standard 105 thermoplastic or equivalent, color coded per corresponding wiring
diagram.
3

SECTION II. – INSTALLATION PROCEDURE
This equipment shall be installed and wired in accordance with regulations of the National
Board of Fire Underwriters, National Electric Code, and local governing bodies. The
following recommendations are not intended to supplant any requirements of federal,
state, or local codes having jurisdiction. Authorities having jurisdiction should be consulted
before installations are made. Local codes may require additional safety controls and/or
interlocks.
A. HANDLING THE EQUIPMENT
The Aeroflo unit has been designed for rigging and handling through the use of
special lifting lug hooks installed on the top of each section, and to not attempt to use
fork lift(s) to install sections. As explained previously, the unit is designed for shipping
in three sections. The fan section, burner section, and discharge plenum section must
be reassembled in the field.
When unloading and setting the heater section, use the lifting lugs on the corners
provided or move the sections on rollers. Hooks, jacks, or chains must not be used
around the casing, exhaust fan, or main control panel. DO NOT LIFT UNIT USING
COMBUSTION CHAMBER BRACKETS.
For convenience in shipping, the discharge plenum section sits on top of the fan
section. Please note that the lifting lugs on the rear of the fan section are
manufactured so that the burner section will fit on the fan section only one way.
Figure 1 depicts a typical unit assembly.
To be properly set, the Aeroflo unit should be placed on a solid foundation and set
exactly as detailed later.
During transit, unloading, and setting of the unit, bolts and nuts may have become
loosened, particularly in the pillow block ball bearing assemblies on the fan section. It
is recommended that all nuts and set screws be tightened. Turn fan shafts by hand to
make certain that propeller fan does not rub against fan venturi, and that bearing lock
rings are tight.
Open the cover on the electrical control box located near the middle on the side of the
burner section. Box can be opened by turning main disconnect switch to the “off”
position. Inspect all wire terminals and wiring terminations to ensure that all
connections are tight.
B. POSITIONING THE UNIT
Install factory supplied gasket between fan section and heater section prior to stacking
sections on top of each other.
Locate the heater exactly level, making certain the minimum clearance is maintained
between the heater, and any combustible material. The Underwriters Laboratories
Inc., listing of the heater stipulates the following clearances: 48” from main control
panel located at the burner end, 18” at the rear, both sides and top. The exhaust
stack clearance must be 18”. See page 11 for stack details.
For convenient access for maintenance, provide 24” clearance at the right side, as
seen when facing the burner, and 36” at the rear. Position the heater, if practical, with
the left hand side (as seen from burner end) next to any adjacent wall
4

Note: Over-all final dimensions may differ from those
stated in "Dimensions" table.

C. LOCATION OF ACCESSORIES
Where applicable, standard or optional accessories will be placed inside the fan
section of the unit for shipment, and must be removed and installed by the
mechanical or electrical contractor.
D. ELECTRICAL CONNECTIONS
All wiring must comply with all applicable local, state, provincial, and national electric
codes. Since shipment of unit requires disassembly after factory flame test,
reconnection of main fan motor leads will be required in the field. Connect electrical
wires (supplied in factory furnished conduit) to secondary side of main fan motor
starters. All motor leads are tagged to facilitate rewiring in the field. See wiring
diagram provided with equipment. Complete all wiring to any optional accessories as
shown on the electrical wiring diagram as required before applying voltage to the unit.
The total amperage of the main disconnect switch, blower motor, and control circuit
transformer fusing is affected by the addition of 25% to the full load amps as required
by the National Electric Code.
Check the supply voltage before energizing the unit. The maximum voltage variations
should not exceed ± 10%. Phase voltage unbalance must not exceed 2%.
E. PIPING CONNECTIONS
All gas piping connections are not shown in this manual because of the many
manifold arrangements available due to approval code requirements and different
types of modulation. All piping must comply with “Standards of National Board of Fire
Underwriters” and all applicable local codes. Contact factory if exact piping
dimensions are required. Protective pipe caps are furnished on manifolds for
shipment from factory; these caps should be removed for installation.
Run correctly sized piping to unit. Install manual gas hand shut-off valve and gas
pressure regulator if not already installed. Please note that gas line pressure must be
as shown on specification plate when unit is operating at full input.
1. Fuel Piping – Gas models
Figure 2 presents a table of gas piping sizes for varying flow rates. A typical Hi-
Lo-Off gas piping manifold is shown in Figure 3. Gas burner connection will vary
between 1” and 3” depending on the Aeroflo model and type of gas.
On gas systems, vent pressure regulator(s) and vent valve (if included with unit)
to outside of building. With vent pipe outside, install a proper vent cap and/or
screen to prevent entrance of foreign material and plugging.
6

GAS FLOW CAPACITY (CFH)
Iron Pipe Size (IPS) Inches
Length of
Pipe
(Equiv. Ft.) 1/2 3/4 1 1-1/4 1-1/2 2 3 4 6 8
15 76 172 345 750 1220 2480 6500 13880 38700 79000
30 52 120 241 535 850 1780 4700 9700 27370 55850
45 43 99 199 435 700 1470 3900 7900 23350 45600
60 38 86 173 380 610 1290 3450 6800 19330 39500
75 77 155 345 545 1120 3000 6000 17310 35300
90 70 141 310 490 1000 2700 5500 15800 32250
105 65 131 285 450 920 2450 5100 14620 29850
120 120 270 420 860 2300 4800 13680 27920
150 109 242 380 780 2090 4350 12240 25000
180 100 225 350 720 1950 4000 11160 22800
210 92 205 320 660 1780 3700 10330 21100
240 190 300 620 1680 3490 9600 19740
270 178 285 580 1580 3250 9000 18610
300 170 270 545 1490 3000 8500 17660
450 140 226 450 1230 2500 7000 14420
600 119 192 390 1030 2130 6000 12480
A. Pressure: 1/2# or Less
GAS FLOW CAPACITY (CFH)
Iron Pipe Size (IPS) Inches
Length of
Pipe
(Equiv. Ft.) 1 1-1/4 1-1/2 2 3 4 6 8
50 244 537 832 1680 5018 8464 22472 41516
100 173 380 588 1188 3549 5986 15894 29364
150 141 310 480 970 2896 4885 12972 23965
200 122 268 416 840 2509 4232 11238 20760
250 109 240 372 751 2244 3785 10050 18567
300 99 219 339 685 2047 3454 9170 16943
400 86 189 294 594 1774 2992 7945 14679
500 77 169 263 531 1587 2677 7108 13132
1000 54 119 185 375 1121 1891 5022 9279
1500 44 97 151 309 915 1544 4101 7577
2000 38 84 131 265 793 1338 3554 6567
B. Pressure: 1/2# to 1#
Figure 2 – Gas Flow Capacity for Piping of
Different Sizes and Lengths
7

F. EXHAUST DUCT CONNECTION
Installation of exhaust stack must comply with regulations of the National Board of
Fire Underwriters and local governing bodies.
The exhaust stack, exhaust stack connector, exhaust stack support and
miscellaneous items related to the exhaust stack are to be supplied and installed by
others.
Connect the exhaust stack to the heater breeching box and run stack through roof
as shown in Figure 4. Avoid use of long horizontal exhaust pipe runs; the exhauster
fan has ample capacity for venting the heater, but cannot perform satisfactorily
against strong back drafts or excessive stack resistance.
G. COMBUSTION AIR OPENINGS
When the heaters are installed in a separate heater room with fresh air and return
air ducts running direct to the base of the heater, or when the plant is under a high
negative pressure condition, provisions should be made for an outside source of
combustion air. A conservative rule of thumb for estimating the inlet area required
is 90 square inches per 1,000,000 BTU/HR heater output. The following table lists
the recommended free area of vent opening in the outside wall for various heater
sizes.
HEATER SIZE
MBH OUTPUT
AREA OF COMBUSTION AIR
INTAKE OPENING – SQ. INCHES
CONNECTING DUCT
DIAMATER - INCHES
1000 90 11
1250 113 12
1500 135 13
1750 158 14
2000 180 14
2250 202 16
2500 225 18
2750 248 18
3000 270 19
3250 292 20
3500 315 20
4500 405 24
9