Series 2000 Downwind Heater Downwind Series 2000 Centrifugal Heater Installation And Operating Instructions MODEL # CH__ - __ __ - __ __ - 2 __ (HIGH) MODEL # CL__ - __ __ - __ __ - 2 __ (LOW) Owner's Manual PNEG-591 1
Series 2000 Downwind Heater 2
TABLE OF CONTENTS Series 2000 Downwind Heater Safety ..........................................................................................................................4 Series 2000 Heater Installation.........................................................................................6 High Temperature Heater Specifications................................................................6 Low Temperature Heater Specifications................................................................
SAFETY Series 2000 Downwind Heater SAFETY FIRST General Safety Statements The GSI Group Inc’s Principal concern is your safety and the safety of others associated with grain handling equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems which may be encountered by the operator and other personnel.
SAFETY Series 2000 Downwind Heater Roof Damage Warning And Disclaimer GSI 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. GSI DOES NOT RECOMMEND THE USE OF DOWNWARD FLOW SYSTEMS (SUCTION). SEVERE ROOF DAMAGE CAN RESULT FROM ANY BLOCKAGE OF AIR PASSAGES.
SPECIFICATIONS Series 2000 Downwind Heater Centrifugal Heater Specifications Hi-Temp Hi-Temp Lo-Temp Model 10-15HP 20-40HP All units BTU Rating 2225000 4500000 500000 Weight 145 145 135 Maximum Fuel flow (GPH) 24 49 N/A Orifice size 0.2188 0.3125 N/A Mod Valve Bypass Orifice Blue Aluminum Yellow Minimum operating pressure 1 1 N/A Maximum operating pressure 15 15 N/A Minimum line size 3/8" 3/8" N/A Maximum Fuel flow (CFH) 931 1898 210 Orifice size 0.2188 0.
Series 2000 Downwind Heater HEATER INSTALLATION Air Pressure Switch and Temperature Sensor Box Installation 1. Using air switch box as a guide, mark 2 holes on plenum side wall appproximately 24" to right of transition centered up and down in plenum. 2. Drill air switch filter hole 5/8" diameter for snug fit. Drill temperature sensor hole 5/8" or larger to accommodate mounting nut. 3. Mount Box to Bin using (4) self drilling screws 4. Caulk between housing and sidewall to seal.
HEATER INSTALLATION Series 2000 Downwind Heater Bin Configuration IMPORTANT! When mounting (2) heaters on a bin it is imperative that they be situated as illustrated in this drawing. Plenum thermostat must be to the right of master heater and master heater must be to the right of slave heater. THIS TABLE IS NOT INTENDED AS A DRYING GUIDE. IT SHOULD BE USED AS A REFERENCE FOR SETTING MAXIMUM PLENUM TEMPERATURE FOR SAFE OPERATION.
HEATER INSTALLATION Series 2000 Downwind Heater Wiring Heater Unit 1. Be sure fan unit is installed and wired to meet local codes. Be sure equipment is well grounded (see page 10). 2. A separate neutral is required for 120 volt heater circuit in 220 volt 1PH and 3PH fan units. For 460 volt fan units a separate 120 volt power supply or transformer is required. 3. Run 5-wire black cord from heater unit to fan unit and se- Figure 2: Wiring diagram for the fan and heater unit. cure to fan. shuts down.
HEATER INSTALLATION Series 2000 Downwind Heater Machine To Earth Ground It is very important that a machine to earth ground rod be installed at the fan. This is true even if there is a ground at the pole 15 feet away. This ground needs to be as close to the fan as possible, but no more than 8 feet away. The ground rod should be connected to the fan control panel with at least a #6 solid bare copper ground wire, or in accordance with local requirements.
HEATER INSTALLATION Series 2000 Downwind Heater Standard electrical safety prac- IMPORTANT! Do not use pro- tices and codes should be used pane tanks that have previ- when working with a heater. ously been used for ammonia Refer to the National Electric unless they have been purged Code Standard Handbook by ALWAYS DISCONNECT the National Fire Protection AND LOCK OUT Association. A qualified elec- POWER trician should make all wiring BEFORE WORKING ON installations.
HEATER INSTALLATION Series 2000 Downwind Heater Figure A Installing Optional Humidity Sensor 1. Humidity sensor should be mounted 6-8" right of the airswitch/temperature sensor box. See Figure A. 2. Using sensor as a guide drill or knock-out 7/8" diameter hole in the center of the plenum on the bin sidewall. If you are using sensor to sense drying air humidity. Figure B 12 3. Insert pipe nipple from sensor housing through hole in side wall and use selfdrilling screws to mount to sidewall.
Series 2000 Downwind Heater OPERATING PROCEDURE The control panel display showing initial start up. Standard electrical safety practices and codes should be used when working with a heater. Refer to the National Electric Code Standard Handbook by the National Fire Protection Association. A qualified electrician should make all wiring installations. ALWAYS DISCONNECT AND LOCK OUT POWER BEFORE WORKING ON OR AROUND HEATER Power Up All safety and high limit switches are checked upon power up.
OPERATING PROCEDURE Series 2000 Downwind Heater Normal Operating Displays With Heater Not Running The main display shows the plenum temperature. If the dryer has not been running, the display should show outside temperature. The control is preset at the factory to display temperature in centigrade or fahrenheit. "AIRFLOW" or "NO AIRFLOW" is displayed if air is flowing or not flowing. "RX TX" (receive, transmit) is displayed if multiple heaters are connected.
Series 2000 Downwind Heater OPERATING PROCEDURE Starting The Dryer After heater power is turned on, the fan must be turned on. Attempting to start the dryer without the air switch indicating there is airflow will cause an airflow alarm to go off when the start switch is depressed. The airflow alarm is simply the entire display going blank, and the "NO AIRFLOW" message flashing for a few seconds. The display must show "AIRFLOW" before the dryer can be started.
OPERATING PROCEDURE 16. When the burner ignites the display should read "HI-FLAME " at the left of the display. Loosen the nut on the main regulator and turn screw in, to increase pressure and out to decrease pressure. The pressure gauges should be set at 10-15 lbs. for LP units, or 4-6 lbs.. for natural gas units. (use the charts on the following pages to set pressure) 17. Press the "PROGRAM TEMPERATURE" button to change the high limit set point. Press it again to change the "CYCLE SET POINT".
OPERATING PROCEDURE Series 2000 Downwind Heater 10-15 hp Units BTUs Per Gauge Pressure (psi) PROPANE MODELS (Approximate) High Temperature 10-15hp 7/32" (0.
OPERATING PROCEDURE Series 2000 Downwind Heater 20-40 hp Units BTUs Per Gauge Pressure (psi) PROPANE MODELS (Approximate) High Temperature 20-40hp 5/16" (0.
OPERATING PROCEDURE Series 2000 Downwind Heater 20-40 hp Units BTUs Per Gauge Pressure (psi) NATURAL GAS MODELS (Approximate) High Temperature 20-40hp 15/32" (0.469") Orifice OPERATING PRESSURE (psi) 1 ALL MODELS 2 3 4 5 6 7 1,597,824 2,266,320 2,770,656 3,195,648 3,573,216 3,919,776 4,234,416 Gauge Pressure (psi) Required to Maintain Temperature (Approximate) (20-40 hp High Temperature Natural Gas Units Only) Heat Rise (°F) Fan Static Model Pressure 60 80 100 120 140 160 180 2" 0.
OPERATING PROCEDURE Series 2000 Downwind Heater Lo-Temp Units BTUs Per Gauge Pressure (psi) PROPANE MODELS (Approximate) Low Temperature All hp 7/64" (0.109") Orifice OPERATING PRESSURE (psi) ALL MODELS 2 4 6 8 10 12 14 15 203,405 287,160 351,771 409,203 457,063 497,744 538,425 555,176 Lo-Temp Units BTUs Per Gauge Pressure (psi) NATURAL GAS MODELS (Approximate) Low Temperature All hp 5/32" (0.
AIR PRESSURE SWITCH Series 2000 Downwind Heater Adjusting the Air Pressure Switch 1. Air pressure switch must be adjusted so that it will activate with lowest level of grain that will be dryed in bin. 2. Put grain in bin to level desired (low). 3. With heater on and fan off display on heater should read "no airflow". 4. Start fan. Heater display should now read "airflow". 5.
OPERATING PROCEDURE Series 2000 Downwind Heater Adjusting The Vaporizor 1. Vaporizer should be adjusted so the vapor pipetrain runs warm to the touch (100°-120°F). 2. Loosen 5/16" bolt on adjustment bracket. 3. Swivel vaporizer away from flame if running too hot, closer to flame if too cold. 4. Move vaporizer only 1" at a time and allow a few minutes for tem perature to equalize. 5. Tighten 5/16" bolt and watch heater run for several minutes to verify adjustment.
Series 2000 Downwind Heater The limits are continuously checked during the drying operation. A limit switch open or any other error condition will cause the dryer to shutdown, and the fan will be shutdown. If a limit opens, or an error condition occurs during drying, the control will lockup in the error display mode. Power must be shut off and back on to the control to clear the error condition-even if the error or limit that caused the shutdown has been corrected.
OPERATING PROCEDURE Series 2000 Downwind Heater On hi-lo units when the unit reaches cycle set point, the flame will switch to lo-flame and unit will not cycle back to hi-flame until (Set Point minus Temperature Differential) is reached. Temperature differential would normally be set for 10-15 degrees F for high temp units, and 2-5 degrees F for lo-temp units. Humidity Differential--The upper right cursor is flashing indicating the mode.
Series 2000 Downwind Heater OPERATING PROCEDURE 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.
FACTORY CONFIGURATION Configuration Dip Switches (Normally Done At GSI) These switches are used to configure the heater control for various types of heaters. Stand alone heater with no slaves, all dip switches in the off state. Series 2000 Downwind Heater Multiple heaters connected together through the serial link. Master with one slave-dip switch 7 on/all others off. Slave #1-dip switch one and three on/all others off. Master with two slaves-dip switch 8 on/all others off.
ERROR CONDITIONS Series 2000 Downwind Heater Limit Switches The following limit switch errors light up individually on the heaters LCD screen: PLENUM, HOUSING, VAPOR, TEMP HI LIMIT. Note: When a shutdown does occur due to an error condition, the amount of time elapsed since the shutdown can be viewed by pressing the down arrow switch (up to 218 Hours).
HEATER SERVICE Series 2000 Downwind Heater All Airstream heaters are constructed of durable weather-resistant materials, so a minimum amount of service should be required; however before the unit is started for the first time each season there are a few items that need to be checked out. All damaged parts should be repaired or replaced. 1. Disconnect and lock out power to fan and heater. Open control box lid and inspect all components for moisture, vibration or rodent damage.
Series 2000 Downwind Heater WIRING DIAGRAM 29
HEATER PARTS Series 2000 Downwind Heater 10-15 Dw High Temp Heater Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 NS NS 30 HF-7076 HF-7288 HF-7380 HF-7379 HF-7287 HF-7063 CD-0238 HF-7201 HF-7204 HF-7101 CD-0187 *THH-4179 HF-7290 HH-7035 HF-7083 HF-7034 HF-7027 THH-4071 HH-3854 HH-3670 S-7259 HF-7079 HF-7020 HF-7297 HF-7032 HF-7023 HF-7261 HF-7263 10-15 HP Housing Assembly Access Side Cover Plastic View Window Access Panel Cover Plate Access Panel Holders 10-15 Diverter Plat
HEATER PARTS Series 2000 Downwind Heater 10-15 Dw Low Temp Heater Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20 21 22 23 24 25 NS NS HF-7076 HF-7288 HF-7380 HF-7379 HF-7287 HF-7063 CD-0238 HF-7201 HF-7204 HF-7101 CD-0187 *THH-4179 HF-7290 HF-7072 HF-7071 HF-7070 HF-7035 HF-7036 HF-7069 THH-4071 HH-3854 HH-3670 S-7259 HF-7079 HF-7297 HF-7032 HF-7261 HF-7263 10-15 HP Housing Assembly Access Side Cover Plastic View Window Access Panel Cover Plate Access Panel Holders 10-15 Diverter Plate Ign
HEATER PARTS Series 2000 Downwind Heater 20-30 Dw High Temp Heater Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 NS NS 32 HF-7077 HF-7288 HF-7380 HF-7379 HF-7287 HF-7064 CD-0238 HF-7201 HF-7204 HF-7102 CD-0187 *THH-4179 HF-7300 HH-7035 HF-7083 HF-7034 HF-7027 THH-4071 HH-3854 HH-3670 S-7259 HF-7079 HF-7020 HF-7297 HF-7032 HF-7023 HF-7261 HF-7263 20-30 HP Housing Assembly Access Side Cover Plastic View Window Access Panel Cover Plate Access Panel Holders 20-30 Diverter Plate
HEATER PARTS Series 2000 Downwind Heater 20-30 Dw Low Temp Heater Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20 21 22 23 24 25 NS NS HF-7077 HF-7288 HH-2020 HF-6914 HF-7287 HF-7064 CD-0238 HF-7201 HF-7204 HF-7102 CD-0187 *THH-4179 HF-7300 HF-7072 HF-7071 HF-7070 HF-7035 HF-7036 HF-7069 THH-4071 HH-3854 HH-3670 S-7259 HF-7079 HF-7297 HF-7032 HF-7261 HF-7263 20-30 HP Housing Assembly Access Side Cover Plastic View Window Access Cover Plate Access Panel Holders 20-30 Diverter Plate Ignitor (
HEATER PARTS Series 2000 Downwind Heater 40hp Dw High Temp Heater Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 NS NS 34 HF-7472 HF-7288 HF-7380 HF-7379 HF-7287 HF-7140 CD-0238 HF-7201 HF-7204 HF-7102 CD-0187 *THH-4179 HF-7304 HH-7035 HF-7083 HF-7034 HF-7027 THH-4071 HH-3854 HH-3670 S-7259 HF-7079 HF-7020 HF-7297 HF-7032 HF-7023 HF-7261 HF-7263 40 HP Housing Assembly Access Side Cover Plastic View Window Access Panel Cover Plate Access Panel Holders 40 HP Diverter Plate Ign
HEATER PARTS Series 2000 Downwind Heater 40hp Dw Low Temp Heater Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20 21 22 23 24 25 NS NS HF-7472 HF-7288 HH-2020 HF-6914 HF-7287 HF-7140 CD-0238 HF-7201 HF-7204 HF-7102 CD-0187 *THH-4179 HF-7304 HF-7072 HF-7071 HF-7070 HF-7035 HF-7036 HF-7069 THH-4071 HH-3854 HH-3670 S-7259 HF-7079 HF-7297 HF-7032 HF-7261 HF-7263 40 HP Housing Assembly Access Side Cover Plastic View Window Access Cover Plate Access Panel Holders 40 Diverter Plate Ignitor (2 Requi
HEATER PARTS Series 2000 Downwind Heater Series 2000 DW Gas Heater Control Box Parts Key 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 36 Part Number HF-7316 *HF-7276RH HF-7276H HH-1442 HF-7277 HF-7255 HH-1093 F-942 HH-1092 FH-1310 HF-7414 HF-7454 HF-7439 HF-7455 DC-821 Description Control Box Housing (Series 2000) *Series 2000 rebuilt board assembly (w/decal) Series 2000 board assembly (w/decal) Toggle Switch Switch Boot Ballast Resistor Transformer 2 pole Control Box Lid High Limit Switch 180 Degree Cord Connec
HEATER PARTS Series 2000 Downwind Heater Air Switch Temperature Sensor Box Key 1 2 3 4 5 6 7 8 NS NS NS Part Number HF-7414 DC-1103 HF-7461 HH-7063 HF-7236 HF-7460 HF-7458 HF-7459 D03-0322 HF-7462 HF-7471 Description Recessed Plastic Plug Adjustment Decal Box Lid Air Pressure Switch Thermistor Temp Sensor Switch Mounting Bracket Box Half (Requires 2) Bin Mounting Plate Filter Air Switch Assembly w/ Temp Sensor Air Switch Assembly w/o Temp Sensor LBS. KGS. 0.10 0.05 0.02 0.01 0.88 0.40 1.00 0.45 0.
HEATER PARTS Series 2000 Downwind Heater Dw Propane Vapor Pipetrain Parts 1 2 3 4 5 6 7 8 9 38 TFC-0023 HH-3670 TFC-0032 HH-2029 S-3853 HH-2984 HH-2653 HH-1251 HH-2028 1/2" 0-30 PSI Regulator (Deluxe, Sr 2000) 1/2" x 2 1/2" Nipple 1/2" Solenoid (Deluxe, Sr.
HEATER PARTS Series 2000 Downwind Heater Dw Natural Gas Vapor Pipetrain Parts 1 2 3 4 5 6 7 8 9 TFC-0051 THH-4136 TFC-0081 THH-4121 THH-4158 D08-0022 D67-0008 HF-7230 HH-7064 3/4" Ball Valve 3/4" x 3" Nipple 3/4" Solenoid (Deluxe, Sr 2000) 3/4" Close Nipple 3/4" x 1/4" x 3/4" Tee 15 PSI Gauge 3/4" Strainer 3/4" Female Union 3/4" Modulating Valve (Optional) 39
HEATER PARTS Series 2000 Downwind Heater Dw Propane Vapor Hi-lo Pipetrain Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 40 TFC-0023 HH-3670 TFC-0032 HH-2029 HH-1453 THH-4067 THH-4127 THH-4032 HH-2984 TFC-0030 HH-7019 HH-1251 HH-2028 1/2" 0-30 PSI Regulator (Deluxe, Sr 2000) 1/2" x 2 1/2" Nipple 1/2" Solenoid (Deluxe, Sr 2000) 1/2" x 1 1/2" Nipple 1/2" x 1/2" x 1/2" Tee 1/2" Street Elbow 1/2" Cross 1/2" x 1/4" Reducer Bushing 30 PSI gauge 1/2" Ball Valve 1/2" Gas Hose 1/2" Strainer 1/2" Female Union
HEATER PARTS Series 2000 Downwind Heater Dw Natural Gas Hi-lo Pipetrain Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 TFC-0051 THH-4136 TFC-0081 THH-4121 THH-4174 THH-4066 THH-4068 THH-4042 D08-0022 D07-0028 HH-2029 TFC-0030 THH-4067 HH-7019 D67-0008 HF-7230 THH-4125 3/4" Ball Valve 3/4" x 3" Nipple 3/4" Solenoid (Deluxe, Sr 2000) 3/4" Close Nipple 3/4" x 3/4" x 1/2" Tee 3/4" Street Elbow 3/4" Cross 3/4" x 1/4" Reducer Bushing 15 PSI Gauge 3/4" x 1/2" Reducer Bushing 1/2" x 1 1/2" Nipple 1/2" Ball Va
HEATER PARTS Series 2000 Downwind Heater Dw Lp Pipetrain Parts 1 2 3 4 5 6 7 8 9 10 42 HH-1251 D07-0019 TFC-0030 HH-4845 TFC-0092 THH-4023 THH-4058 CD-0197 HH-7013 D07-0009 1/2" Strainer 1/2" x 1 1/2" Nipple Sh. 80 1/2" Ball Valve 1/4" Relief Valve 1/2" Solenoid Valve 300 PSI 1/2" x 1/4" Reducer Bushing 1/2" x 1/2" x 1/2" Tee Sh.
Series 2000 Downwind Heater NOTES ______________________________________________________________________________________________________________ _____________________________________________________________________________________________________ __________________________________________________________________________________________________________ ______________________________________________________________________________________________________ _____________________________________________________
WARRANTY Series 2000 Downwind Heater THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF 36 MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH PRODUCTS. GSI'S ONLY OBLIGATION IS, AND PURCHASER'S SOLE REMEDY SHALL BE FOR GSI, TO REPAIR OR REPLACE, AT GSI'S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI'S SOLE JUDGMENT, CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP.
Series 2000 Downwind Heater 1004 E. Illinois St.
