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Low Temperature Upstream Heater VP and NG-Fired Heater Installation, Operation, and Parts Manual This manual applies to: GGH-8390/GGH8390-50 INSTALLATION AND WIRING MUST BE IN ACCORDANCE WITH CEC, NEC, AND LOCAL ELECTRICAL CODES Read this manual before using product. Failure to...
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WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. - Do not store or use gasoline or other flammable vapours an d liquids in the vicinity of the crop dryer.
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This product has been designed and manufactured to meet general engineering standards. Other local regulations may apply and must be followed by the operator. All personnel must be trained in the correct operational and safety procedures for this product. Use the sign-off sheet below to record initial and periodic reviews of this manual with all personnel.
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER GNA-2069 R1...
Keep this manual handy for frequent reference and to review with new personnel. A sign-off form is provided on the inside front cover for your convenience. If any information in this manual is not understood or if you need additional information, please contact AGI or your representative for assistance.
1. INTRODUCTION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 1.2. Intended Use The upstream heater is intended for use as listed below and described throughout this manual. Use in any other way is considered contrary to the intended use and is not covered by the warranty. Intended use for the upstream heater •...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 2. SAFETY 2. Safety 2.1. Safety Alert Symbol and Signal Words This safety alert symbol indicates important safety messages in this manual. When you see this symbol, be alert to the possibility of injury or death, carefully read the message that follows, and inform others.
2. SAFETY LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 2.3. Heater Safety Fire and explosion hazards, as well as carbon monoxide poisoning could occur if the heater is misused. To avoid serious injury or death: • Shut off and lock out or disconnect power and close valve at gas source before inspecting or servicing the heater, or when not in use.
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 2. SAFETY 2.5. Grain Bin Fires To Prevent Fires: • Use all equipment (fan, heater, air system and bin) as it is intended to be used. • Ventilate, purge all contaminates, and allow burner, and drying areas to cool inside the heater, in the heater area and the grain bin before any persons enter these areas.
2. SAFETY LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 2.6. Drives and Lockout/Tagout Safety Inspect the power source(s) before using and know how to shut down in an emergency. Whenever you service or adjust your equipment, make sure you shut down your power WARNING source and gas supply and follow lockout and tagout procedures to prevent inadvertent start-up and hazardous energy release.
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 2. SAFETY 2.9. Safety Decals • Keep safety decals clean and legible at all times. • Replace safety decals that are missing or have become illegible. See decal location figures that follow. •...
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2. SAFETY LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Table 1. Safety Decals Part Number Description 601-1992 NOTICE (Heater shroud, visible near the product ID) To prevent possible roof damage, ensure that all roof vents are open and unobstructed. Do not operate aeration fan if it is possible that the roof vents could ice up.
MOUNTING BRACKET CONNECTION POINT SCREEN BRACKET BODY SHROUD HALF GUARD SCREEN (SUPPLIED WITH FAN) Note This heater uses vapor propane or natural gas, not liquid propane. Delivering liquid propane to the heater will void the AGI Heater Warranty. GNA-2069 R1...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 3. FEATURES 3.3. Fuel Train, Burner, Stablizing Frame, and Control Box Assemblies DIN CONNECTOR WITH POWER CORD FLEX RUNNING FROM ORIFICE CONDUIT CONTROL BOX TO NIPPLE THE SOLENOID VALVE SOLENOID VALVE FUEL TRAIN MANUAL SHUT OFF...
3. FEATURES LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 3.4. Burner Assembly 1/2” X 22” STAINLESS STEEL BURNER PIPE FLAME SPREADERS TOP END BURNER PLATE IGNITER ADJUSTABLE BURNER SIDE PLATE BURNER PORT BOTTOM END BURNER PLATE 1/2” STAINLESS STEEL PIPE CAP GNA-2069 R1...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 3. FEATURES 3.5. Control Box Assembly LOCATION FOR CONTROL BOX FENWAL OPTIONAL FUSE INDICATOR TERMINAL ENCLOSURE CONTROL BOARD TRANSFORMER LIGHT BLOCK ON/OFF SWITCH LOCATION FOR OPTIONAL THERMOSTAT CONTROLLER POWER CORD CORD TO SOLENOID GNA-2069 R1...
Inspect the upstream heater and accessories on receipt to ensure that all items have arrived and that none are damaged. Report missing or damaged parts immediately to ensure that proper credit is received from AGI or your distributor/dealer, and to ensure that any missing parts can be shipped quickly to avoid holding up the installation.
• Heaters are equipped with a terminal strip where the customer supplied thermostat, humidistat, or combination unit for controlling the heater output should be wired. • AGI recommends that all fan/heaters are connected to a ground rod. Check previously installed units for proper grounding.
It also provides the necessary grounding for operation and helps provide for a long life of control circuits. • AGI does not supply or sell ground rods and wires. Please contact your local electrical parts supplier. • AGI recommends that the rod not be driven into dry ground.
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. INSTALLATION 6. AGI recommends previously installed unit be checked for proper grounding. 4.5. Fuel Supply Important • Hire a professional to plan, set up, and connect the chosen fuel supply. The system must include an emergency shut-off valve.
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4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Figure 3. Example Supply Tank Liquid To Heater Table 2. Vapor Pressure at Various Temperatures Outside Temperature Vapor Pressure Volume Fluid Volume BTUs per Cubic Hour Cubic Feet Degrees Degrees Gallons per Liters per...
When using multiple fans in one bin you must prevent reverse rotation of idle fans or the fan motors may be damaged. Reverse rotation can be prevented by ensuring simultaneous startup of the fans or by employing shutters that shield idle fan blades from moving air. Contact your AGI dealer for the appropriate size shutter.
4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4.7. Installation of Heater and Heater Components • Failure to install the heater and aeration fan in proper orientation will cause safety devices located in the heater unit to fail. This may result in serious personal injury and property damage and will void the warranty.
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. INSTALLATION 3. The airflow of different fans can vary greatly and some experimentation may be necessary to find the proper burner side location and burner pressure setting to get consistent ignition and an efficient burn. •...
4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4.7.3 Install the Guard and Control Box 1. Reinstall the fan guard attaching it to the heater shroud brackets (see Figure 8). Use the provided bolts and nuts. 2. Install the control box to the fan in a convenient location using the provided self-drilling screws (see Figure 9).
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. INSTALLATION 4.7.4 Install the Orifice 1. The supplemental heater is supplied with a 0.0938", 0.0625", and 0.1563" orifices supplied in the parts bag. Figure 2. See Section 5.4 – Upstream Supplemental Heater Temperature Rise on page 44 which offers orifice size recommendations for achieving the desired temperature rise.
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4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Table 3. Recommended Orifice Size for Propane and Natural Gas Per Fan Size 1,750 rpm Orifice Centrifugal Wheel Diameter Propane Natural Gas 27" 0.0625" 0.0938" (686 mm) (1.5875 mm) (2.38125 mm) 27"...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. INSTALLATION 4.7.5 Install Air Switch Line Figure 11. Air Switch Line (For <50HP ) GGH-8390XX AIR SWITCH GAP BETWEEN COPPER TUBE CHANGES BASED ON FAN 90° COPPER TUBE FITTING 8 " FAN INLET CONE HEATER...
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4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Figure 12. Air Switch Line (for 50HP) GGH-8390XX-50 AIR SWITCH 90° COPPER TUBE FITTING 16 " 16 " FAN INLET CONE HEATER HOUSING SECTION A-A SCALE 1 : 6 GNA-2069 R1...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. INSTALLATION 4.7.6 Temperature Probe Installation Thermostat Probe holder Temperature probe Self tapping screw Probe wire Probe wire 1. Mark a location on a peak of the bin sheet. Important Mark a location on a peak of the bin sheet (Must be below the perforated floor, approximately 6 inches up from the concrete The location must be below the perforated floor.
4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4.8. Connect the Gas Supply This procedure describes how to connect propane or natural gas to the heater, test for piping system pressure, and test for gas leaks. Connecting the Gas Hose 1.
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. INSTALLATION 4.9. Adjust the Regulator Adjust the regulator (Figure 13) to dial in the desired temperature based on the temperature rise table (see Section 5.4 – Upstream Supplemental Heater Temperature Rise on page 44).
4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4.11. Programming of Penn & Emerson Electronic Controllers For units with Penn A421ABC and A421AEC series: The basic menu is mainly used to quickly edit the on and off temperature. 1.
SELF DRILLING TEK SCREWS Wiring and Programming the Temperature Control and Sensor 1. AGI recommends that heaters are controlled with an on-off electronic temperature controller. 2. The temperature controller should be hard-wired as shown in Figure 16 Figure 3.
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4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Figure 16. Recommended Location for Ambient Temperature Sensor (Sensor B) Attach the ambient temperature sensor (Sensor B) to the fan guard for the most accurate temperature measurement Figure 17. Wiring of Temperature Sensors Sensor A is the duct sensor to be mounted on the bin.
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. INSTALLATION Program the Controllers 1. Power up the electronic controller and enter the program menu by pressing the menu button and toggling to RELAY 1. RELAY 1 controls the ON/OFF cycle on heater 1. Figure 18.
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4. INSTALLATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 4. Set the sensor to SENSOR A; this ensures the controller will use sensor A - the duct temperature sensor to control temperature. Figure 21. MENU PROGRAM PROGRAM RELAY 1 RELAY 1 SENSOR SENSOR...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 5. OPERATION 5. Operation Before continuing, ensure you have completely read and understood this manual’s Safety section, in addition to the safety information in the section(s) below. 5.1. Operation Safety • Ensure the heater is connected to the appropriate gas supply, and correctly sized orifice is installed.
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5. OPERATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Figure 24. Reset High Temperature Switch First remove the high temperature switch circular cover Then, press the RESET button lightly with a screwdriver to reset Important If using for the first time, follow the checklist in Section 6.4 –...
Reverse rotation can be prevented by ensuring simultaneous startup of the fans or by employing shutters that shield idle fan blades from moving air. Contact your AGI dealer for the appropriate size of shutter. 3. Flip the heater toggle switch to “ON” position.
5. OPERATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 5.4. Upstream Supplemental Heater Temperature Rise Note Temperature rise is based on the theoretical fuel potential only and does not account for temperature rise due to static pressure creation in the fan itself. Note Heater to be used with 1750 rpm centrifugal fans only.
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 5. OPERATION Table 5 Guage Pressure (PSI) Required to Maintain Temperature Rise (Approximate) — Propane (continued) 20 HP TEMPERATURE RISE (°F) Orifice 5°F 10°F 15°F 20°F 25°F 30°F 35°F 40°F .0625 2"...
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5. OPERATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Table 5 Guage Pressure (PSI) Required to Maintain Temperature Rise (Approximate) — Propane (continued) 40 HP TEMPERATURE RISE (°F) Orifice 5°F 10°F 15°F 20°F 25°F 30°F 35°F 40°F .0625 2"...
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 5. OPERATION Temperature Rise — Natural Gas Model Table 6. BTUS PER Guage Pressure (PSI) - Natural Gas Models Orifice 0.0937 59000 61057 74743 86305 96492 105703 114172 122055 129459 0.156 115061 162721 199292...
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5. OPERATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Table 7 Guage Pressure (PSI) Required to Maintain Temperature Rise (Approximate) — Natural Gas Models (continued) 25 HP TEMPERATURE RISE (°F) Orifice 5°F 10°F 15°F 20°F 25°F 30°F 35°F 40°F .0938 2"...
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 5. OPERATION Table 7 Guage Pressure (PSI) Required to Maintain Temperature Rise (Approximate) — Natural Gas Models (continued) 40 HP TEMPERATURE RISE (°F) Orifice 5°F 10°F 15°F 20°F 25°F 30°F 35°F 40°F .0938 2"...
5. OPERATION LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 5.5. Flame Inspection This heater uses a burner that must be functioning correctly in order for the heater to produce the specified BTUs. 1. Inspect the flame. The flame should look blue with an orange tip approximately 2” [51 mm] to 1 1/2” [63.5 mm] long.
• After maintenance is complete, replace all guards, service doors, and/or covers. • Use only genuine AGI replacement parts or equivalent. Use of unauthorized parts will void warranty. If in doubt, contact AGI or your local dealer.
6. MAINTENANCE LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 6.3. Visually Inspect the Upstream Heater Check the following during a visual inspection: 1. Ensure all guards are in place and in good working order. 2. Examine the upstream heater for damage or unusual wear. 3.
• Tampering with the regulator voids the warranty. • Regulator replacement must be performed at the factory or be performed by a qualified gas technician approved by AGI. Death or serious injury due to fire or explosion could result from an improperly connected pressure regulator.
You may also contact an AGI product specialist at 1–800–565–2840. Before you contact them, please have this operation manual and the serial number from your machine ready.
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 7. TROUBLESHOOTING • If the outside red light on control box comes on, and the led light on the Fenwal DSI module flashes momentarily, then skip the steps from 1 to 5, and proceed to step 6 in the Table 8 below.
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7. TROUBLESHOOTING LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Table 8 Check Heater Components (continued) Electrical Schematics on page 63, and verify the connection. No power at L1 Check for power at terminal L1 of check terminations on the Fenwall DSI module.
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 7. TROUBLESHOOTING 7.3. Symptoms/Causes/Solutions Never check for a spark without first shutting off the fuel supply and purging all fuel from the system. Purge the fuel system by shutting off the fuel supply, starting the fan, and cycling the burner ignition sequence 2 to 3 times.
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7. TROUBLESHOOTING LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Table 9 Symptoms, Causes and Solutions (continued) Problem Check Possible Cause Solution A click should be heard or felt when laying hand on the Replace solenoid if not Solenoid not opening solenoid top.
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 8. APPENDIX 8. Appendix 8.1. FENWAL-Related Issues Input Polarity If the system shuts down after the ignition trial period even though a spark is present and the gas valves are open, measure the voltages at L1 and L2 with respect to ground. The voltage at terminal (L1) should be 120 VAC;...
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8. APPENDIX LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER example, 1 VDC equates to 1 microamp or higher while sensing a flame. A negative meter reading indicates that the leads are reversed. Interchanging the meter leads will correct the polarity. Sequence of Operation / Flame Recovery / Safety Lockout •...
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 8. APPENDIX 2. FLAME FAILURE - RE-IGNITION MODE – If the established flame signal is lost while the burner is operating, the control will respond within 0.8 seconds by immediately energizing the H.V. spark for the TFI period in an attempt to relight the flame.
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8. APPENDIX LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Fenwal Troubleshooting Table 10. Troubleshooting Guide Symptom Recommended Actions Miswired No 120 VAC at L1 Control does not start Fuse or circuit breaker fault Faulty control, check LED for fault codes Miswired Faulty thermostat, no voltage at terminal L1 Thermostat on —...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 8. APPENDIX 8.2. Electrical Schematics Note For heaters installed in Canada: All wiring must be done in accordance with the Canadian Electric Code, Part I, CSA C22.1. GNA-2069 R1...
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8. APPENDIX LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER GNA-2069 R1...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 8. APPENDIX 8.2.1 Interlocking Heater to Fan For older model fans not equipped with auxiliary contact on Motor Starter Auxiliary contact Heater Terminal Block 120V White 120V Black Heater Power Cord Contactor Overload 1.
8. APPENDIX LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 8.3. Parts Lists Figure 26. Upstream Low Temperature Heater Assembly UNDER THE COVER Table 12. Upstream Low Temperature Heater Assembly Quantity Description Item Part Number AIR SWITCH 507-1139 (UNDER THE COVER) GUJ-7479 BURNER ASSEMBLY 526-2082...
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 8. APPENDIX Figure 27. Fuel Train Assembly — Main Components FUEL SHUT OFF Know where it is! Table 13. Fuel Train Assembly — Main Components Quantity Description Item Part Number RELIEF VALVE POP UP 1/4'' 26 PSI 527-4836 SOLENOID VALVE 1/2'' DIN CON 528-4849...
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8. APPENDIX LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER Figure 28. Fuel Train Parts Lists 527-2617 STRAINER PROPANE 3127G 1/2" 527-4836 RELIEF VALVE POP UP 1/4'' 26 PSI 527-4837 RELIEF VALVE CAP 1/4'' 528-4849 SOLENOID VALVE 1/2'' DIN CON SD8210H106B 529-3597 FITTING 1/2"...
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 8. APPENDIX Figure 29. Control Box Assembly LID INSIDE Table 14. Control Box Assembly Quantity Description Item Part Number GNJ-7504 IGNITION WIRE 526-1193 CONTROL BOARD 507-1294 TOGGLE ON-OFF SWITCH 510-1120 BUSSMANN FUSEHOLDER Htb-261 507-1293 TOGGLE SWITCH BOOT GZJ-7484...
LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 9. Warranty Except as expressly provided in this agreement, AGI (hereinafter called the Manufacturer) excludes all express or implied warranties, conditions, and obligations of the Manufacturer, whether statutory or otherwise, concerning the quality of the units or their fitness for any purpose.
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LOW TEMPERATURE UPSTREAM HEATER – VP AND NG-FIRED HEATER 9. WARRANTY GNA-2069 R1...
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AGI is a leading provider of equipment solutions for agriculture bulk commodities including seed, fertilizer, grain, and feed systems with a growing platform in providing equipment and solutions for food processing facilities. AGI has manufacturing facilities in Canada, the United States, the United Kingdom, Brazil, South Africa, India and Italy and distributes its products globally.
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