Downwind Centrifugal Heater Installation and Operation Model #:_______________ Serial #:_______________ Owner’s Manual PNEG-588-04 Date: 05-30-13 PNEG-588-04
Check List 1. All wire connections 2. Spark plug gap 0.063 (1/16") 3. Pipe train tightness and gas leaks 4. Flame sensor tight 5. Fuse in place, extra fuse provided 6. Flame out light 7. Indicator light 8. Pressure gauge 9. Regulator adjusted 10. Shut off valve operates correctly 11. Vapor High-Limit 12. Unit cycles ON to OFF 13. Heat rise even across transition 14. Unit cycles HIGH to LOW (HIGH-LOW only) 15. Mod valve holds temperature within 1° (mod units only) 16. All decals and serial number tag 17.
Table of Contents Contents Chapter 1 Introduction .......................................................................................................................................... 4 Chapter 2 Safety ..................................................................................................................................................... 5 Safety Guidelines ..................................................................................................................................
1. Introduction Thank you for choosing a GSI Group product. It is designed to give excellent performance and service for many years. It is the plan of The GSI Group to improve its product whenever possible and practical to do so. We reserve the right to change, improve and modify products at any time without obligation to make changes, improvements and modifications on equipment sold previously. Our foremost concern is your safety and the safety of others associated with this equipment.
2. Safety Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
3. Decals Roof Damage Warning and Disclaimer The manufacturer does not warrant any roof damage caused by excessive vacuum or internal pressure from fans or other air moving systems. Adequate ventilation and/or “makeup air” devices should be provided for all powered air handling systems. The manufacturer does not recommend the use of downward flow systems (suction). Severe roof damage can result from any blockage of air passages.
3. Decals Safety decals should be read and understood by all people in the grain handling area. If a decal is damaged or is missing contact: GSI Decals 1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421 A free replacement will be sent to you. WARNING Part #: DC-1225 Size: 4-7/8" x 2-1/4" Located above access door on heater housing. (See Note Below.) Stay clear of rotating blade. Blade could start automatically. Can cause serious injury. Disconnect power before servicing.
3. Decals DANGER High voltage. Will cause serious injury or death. Lockout power before servicing. DC-1224 DC-535 Part #: DC-535 Size: 2-1/2" x 3.0" Located on the outside of the heater housing near the vaporizer coil on LP units. Part Number: DC-1224 Size: 2-5/8" x 4-5/8" Located on the outside of the control box lid. DANGER HIGH VOLTAGE. Will cause injury or death. Lockout power before servicing. HAUTE TENSION. Causera des blessures ou la mort. Fermez le courant avant l’entretien.
4. Specifications Heater Dimensions Model # IH IW L CHD-15 30-1/4" 19-1/2" 33.00" CHD-30 33-1/4" 21-3/4" 33.00" CHD-40 33-1/4" 23.69" 33.
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5. Installation Vertical Profile Angle Configuration Vertical profile angles have been added to the Downwind Centrifugal Heaters to increase burner performance quality. These angles have been factory installed with the angle configuration of the smallest horsepower fan rated for the heater. As a result, some changes will be required at the time of installation once the fan and heater combination is known. This document describes the proper configurations of the vertical angles inside the heater housing.
5. Installation CF-10 Centrifugal Fan and CHD-15 Model Heater Figure 5B shows the factory configuration. No change is required to the heater. Retrofit applications require holes to be drilled in the upper and lower profile angles and the vertical angle to be installed with the noted hardware.
5. Installation CF-20 Centrifugal Fan and CHD-30 Model Heater Figure 5C shows the factory configuration for the 20 HP application. Here the long leg of the angle points toward the center of the heater to provide a 17" wide opening across the housing at the location of the angles. No change is required to the heater. Retrofit applications require holes to be drilled in the upper and lower profile angles and the vertical profile angles to be installed with the noted hardware.
5. Installation CF-25 Centrifugal Fan and CHD-30 Model Heater Figure 5D shows the configuration for the 25 HP application. The vertical profile angles must be repositioned. Flip each angle end for end and install it with the short leg of the angle pointing toward the center of the heater. This provides a 19-1/2" wide opening across the heater housing at the location of the angles.
5. Installation Heater must be interlocked with fan for safe operation. CAUTION Heater Power Connection 1. Connect power cord to fan control box. 2. Make field connections in fan box as shown in Figure 5E. 3. Connect deluxe thermostat control as shown in Figure 5E. NOTE: Heater control is 120V only. Thermostat must be installed for safe operation. CAUTION Heater power is 120 VAC. Damage will occur if connected to high voltage power source.
5. Installation Deluxe Heater - Second Heater Installation For Deluxe Units Using HF-7318-1 Control Board Two (2) Deluxe Heaters may be connected to one grain drying system and wired so they cycle together. One of the heaters should have a thermostat connected to it as per the installation instructions. That heater will be referred to as the master. The other heater (without the thermostat) will be referred to as the slave. Installation for ON/OFF Units 1.
5. Installation Fuel Connection CAUTION Do not use propane tanks which have previously been used for ammonia unless they have been purged according to procedures of the national LP association. Investigate to be sure that the fuel supply system complies with all local codes for LP gas installations. Liquid Propane Models 1. LP models are designed to run on liquid propane, with liquid draw from the propane tank. Avoid using propane supply tanks that have been use for vapor draw for long periods of time.
5. Installation Bin Configuration Figure 5G Ref # Description A Unload Auger B Plenum Thermostat C Master Heater D Slave Heater IMPORTANT: When mounting two (2) heaters on a bin it is imperative that they be situated as shown in Figure 5G. Plenum thermostat must be to the right of master heater and master heater must be to the right of slave heater.
5. Installation Transition High-Limit Installation 1. Mark location on transition one foot up from the bottom (entrance collar) and centered in the transition. 2. Drill or knock out 7/8" diameter hole on marked location. 3. Install transition high-limit using supplied self-drilling screws. Figure 5H Sensor placement on transition connecting heater to the bin.
5. Installation Plenum Thermostat Installation The plenum thermostat must be ordered separately from the heater unit. 1. Follow installation instructions provided with the thermostat assembly. 2. Position the housing so that the bolt flanges are vertical and the cord exits the housing from the bottom. Mark position. 3. Use six (6) (4.00") or eight (8) (2.66") self-drilling screws to mount the housing to the bin sidewall. DO NOT TIGHTEN COMPLETELY.
6. Operation Operating Temperature Table NOTE: This table is not intended as a drying guide. It should be used as a reference for setting maximum plenum temperature for safe operation.
6. Operation High-Low Heater Operation 1. High-limit and cycling thermostat must be wired into heater control box for heater to operate. 2. Open all manual shut off valves to heater unit. 3. Start fan. This will supply power to heater. 4. Turn thermostat dial to its highest setting. 5. Turn toggle switch ON. Both indicator lights should illuminate indicating power to the control circuit. 6. Heater should now be lit. If not check to see that all gas is ON. 7.
6. Operation Modulating Valve Operation 1. The modulating valve regulates gas flow through the heater based on sensing unit in the plenum and maintains a constant drying air temperature. 2. The sensing bulb of the modulating valve should be mounted through the bin wall with the side reading “top” up. The bulb reacts to temperature. It changes the amount of gas (increase or decrease), burning warmer or cooler depending on the position of the valve SET POINT.
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6. Operation Adjusting the Vaporizer 1. Vaporizer should be adjusted so the vapor pipe train runs warm to the touch (100°-120°F). 2. Loosen 5/16" pivot bolts on adjustment bracket. 3. Tilt vaporizer away from burner to cool. Tilt toward burner to heat. Vaporizer may be raised or lowered for vertical adjustments. 4. Tighten 5/16" pivot bolts to fix vaporizer position. IMPORTANT: Only move vaporizer 1" at a time. Allow heater to run a few minutes for temperature to equalize.
7. Service Seasonal Inspection and Service All parts are made of weather-proof construction and are designed to require a minimum of service; however, we recommend the following items be checked and serviced, as described, before the unit is used each season. Replace any damaged or questionable parts. THESE CHECKS WILL HELP ELIMINATE POSSIBLE MINOR FAULTS AND ASSURE DEPENDABLE OPERATION OF THE EQUIPMENT WHEN IT IS NEEDED. 1.
7. Service 10. LP MODELS ONLY - After heater has been operating for some time and temperatures have stabilized, check temperature of the gas line between outlet side of vaporizer and the gas regulator. If gas line becomes “frosted” with an accumulation of ice build-up, adjust vaporizer slightly closer to the flame. If line reaches a high temperature where it is hot to the touch, adjust vaporizer further away from the flame.
8. Parts List 1. Heater Housing: CHD-15 - (See Page 32.) 2. Heater Housing: CHD-30 and CHD-40 - (See Page 33.) 3. Propane Vapor Pipe Train: All Models - (See Page 34.) 4. Liquid Propane Pipe Train: All Models - (See Page 35.) 5. Natural Gas Pipe Train: CHD-15 - (See Page 36.) 6. Natural Gas Pipe Train: CHD-30 and CHD-40 - (See Page 37.) 7. LP Supply Pipe Train - (See Page 38.) 8. 3/4" High-Low Pipe Train Option - (See Page 39.) 9. 3/4" Modulating Pipe Train Option - (See Page 40.) 10. 1.
8. Parts List Heater Housing: CHD-15 Heater Housing: CHD-15 Parts List Ref # 32 Part # Description 1 HF-7653 Downwind Housing Bottom: 10-15 2 HF-7654 Downwind Housing Side: R.H. 10-15 3 HF-7652 Downwind Housing Top: 10-15 4 HF-7655 Downwind Housing Side: L.H. 10-15 5 HF-7854 Access Panel Downwind Heater - Blank 6 HF-7287 Access Panel Bracket - Downwind Heaters 7 HF-7379 Heater Cover Plate 1996< 8 HF-7380 Window Access 0.
8. Parts List Heater Housing: CHD-30 and CHD-40 Heater Housing: CHD-30 Parts List Ref # Part # Description Heater Housing: CHD-40 Parts List Ref # Part # Description 1 HF-7781 Downwind Housing Bottom: 20-30 1 HF-7803 Downwind Housing Bottom: 40 2 HF-7783 Downwind Housing Side: R.H. 20-30/40 2 HF-7783 Downwind Housing Side: R.H. 20-30/40 3 HF-7780 Downwind Housing Top: 20-30 3 HF-7802 Downwind Housing Top: 40 4 HF-7784 Downwind Housing Side: L.H.
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8. Parts List 3/4" Modulating Pipe Train Option 3/4" Modulating Pipe Train Option Parts List Ref # Part # Description 1 THH-4164 Elbow, 1"-90° Street SCH 40 Black 2 THH-4115 Elbow, 1"-90° SCHED SCH 40 Black 3 THH-4151 Nipple, 1" x 3" SCH 40 Black 4 THH-4059 Nipple, 1" x 5-1/2" SCH 40 Black High-Low or Modulating Valves can be ordered factory installed or added in the field. Field installation requires the removal of the long pipe nipple (See Ref #1 on Page 39 ).
8. Parts List 1.0" Pipe Train Options: High-Low and Modulating High-Low or Modulating Valves can be ordered factory installed or added in the field. Field installation requires the removal of the 1" 90° street elbow (Ref #1). Once removed, the components for the appropriate valve should be added in the same location. 1.0" Pipe train options will require additional support brackets: HF-7575 and THH-4170. Pipe sealant should always be used to prevent leaks. 1.
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8. Parts List Deluxe Heater Control Box Parts List Ref # Part # Description 1 HF-7719 Downwind Heater Box - CNC OPS 2 069-1376-8 Control Box Lid - Poly Blank 3 D03-0696 Latch, Farm Fans Control Box 4 DC-1695 Decal, Heater Plastic Control Box Deluxe 5 90-0009 Lamp, Oil Tight 1/4" TAB 120V 6 HF-7696 Switch 2 Position Selector: Lever 7 D63-0006 Block, Contact N.O.
9. Test Fire Procedure Test Firing Deluxe Burner Control 1. Turn ON power and fuel to the fan and heater. Set the controlling thermostat to call for heat. 2. Start fan and move heater switch to the “ON” position. a. The “FAN ON” indicator light on the board should now be lit. b. If light is not ON, confirm 120V at terminals 19 and 20. If no power exists, check for power at the fuse in the fan control box and all safety high-limit switches.
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11. Miscellaneous Parts by Description 46 Part # Description Part # Description HF-7200 250° Bin High-Limit Assembly HF-7719 Downwind Heater Box - CNC OPS HF-7431 Access Panel Assembly Downwind Heater HF-7653 Downwind Housing Bottom: 10-15 HF-7287 Access Panel Bracket - Downwind Heaters HF-7781 Downwind Housing Bottom: 20-30 HF-7288 Access Panel Downwind Heater HF-7803 Downwind Housing Bottom: 40 D03-0099 Adapter Tab 0.187" x 0.
11. Miscellaneous Parts by Description Part # Description Part # Description 090-1701-3 Screw, MS #10-24 x 1/2" PHS ZN S-7192 Screw, MS #8-32 x 5/8" PHP ZN THH-4117 Nipple, 1" Close SCH 40 Black D03-0247 Wire Tie 5" Panduit #PLT 1.5M-M THH-4059 Nipple, 1" x 5-1/2" SCH 40 Black WR-18GRN/YLW Wire, 18 Gauge Green/Yellow Stranded THH-4032 Nipple, 1/2" Close SCH 40 Black 07098556 Shroud 16" Motor Cord 090-1699-9 Rivet, Pop 1/8" Diameter x 0.
NOTES 48 PNEG-588-04 Deluxe Downwind Heater Installation and Operation
12. Warranty GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
This equipment shall be installed in accordance with the current installation codes and applicable regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.
