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GSI Group Series 2000 Installation And Operating Instructions Manual

Downwind centrifugal heater
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MODEL # CH__ - __ __ - __ __ - 2 __ (HIGH)
MODEL # CL__ - __ __ - __ __ - 2 __ (LOW)
Owner's
Manual
PNEG-591
Downwind Series 2000
Centrifugal Heater
Installation And

Operating Instructions

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  • Page 1: Operating Instructions

    Downwind Series 2000 Centrifugal Heater Installation And Operating Instructions MODEL # CH__ - __ __ - __ __ - 2 __ (HIGH) MODEL # CL__ - __ __ - __ __ - 2 __ (LOW) Owner's Manual PNEG-591...

  • Page 3: Table Of Contents

    Safety ..........................4 Series 2000 Heater Installation..................6 High Temperature Heater Specifications..............6 Low Temperature Heater Specifications..............6 Air Pressure Switch and Temperature Sensor Box............7 Transition Hi-Limit Installation................7 Bin Configuration/Operating Temperature Table...........8 Heater Unit Wiring....................9 Secondary Heater Unit Wiring................9 Machine To Earth Ground..................10 Proper Installation Of The Ground Rod..............10 Previously Installed Units..................10...

  • Page 4: Safety

    SAFETY FIRST General Safety Statements CAUTION 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 CAUTION indicates a potentially hazardous situation as a customer. This manual is to help you under-...
  • Page 5 Roof Damage Warning And Disclaimer GSI DOES NOT WARRANT ANY ROOF DAMAGE CAUSED BY EXCESSIVE VACUUM OR INTERNAL PRES- SURE FROM FANS OR OTHER AIR MOVING SYSTEMS. ADEQUATE VENTILATION AND/OR "MAKEUP AIR" DE- VICES SHOULD BE PROVIDED FOR ALL POWERED AIR HANDLING SYSTEMS.

  • Page 6: Series 2000 Heater Installation

    Centrifugal Heater Specifications Hi-Temp Hi-Temp Lo-Temp Model 10-15HP 20-40HP All units All Models BTU Rating 2225000 4500000 500000 Weight Liquid Models Maximum Fuel flow (GPH) Orifice size 0.2188 0.3125 Mod Valve Bypass Orifice Blue Aluminum Yellow Minimum operating pressure Maximum operating pressure Minimum line size 3/8"...

  • Page 7: Air Pressure Switch And Temperature Sensor Box

    Air Pressure Switch and Temperature Sensor Box Installation 1. Using air switch box as a guide, mark 2 holes on ple- num side wall appproximately 24" to right of transition cen- tered up and down in plenum. 2. Drill air switch filter hole 5/8" diameter for snug fit.

  • Page 8: Bin Configuration/Operating Temperature Table

    Bin Configuration IMPORTANT! When mounting (2) heaters on a bin it is imperative that they be situated as illustrated in this draw- ing. Plenum thermostat must be to the right of master heater and master heater must be to the right of slave heater.

  • Page 9: Heater Unit Wiring

    Wiring Heater Unit...

  • Page 10: Machine To Earth Ground

    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.

  • Page 11: Fuel Connection For Liquid Propane Models

    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 according to procedures of the ALWAYS DISCONNECT...

  • Page 12: Installing Optional Humidity Sensor

    Installing Optional Humidity Sensor Humidity sensor should be mounted 6-8" Insert pipe nipple from sensor housing right of the airswitch/temperature sensor through hole in side wall and use self- box. See Figure A. drilling screws to mount to sidewall. Figure B Using sensor as a guide drill or knock-out 7/8"...

  • Page 13: Series 2000 Operating Procedure

    tion. There is no way to bypass an error condition. It Standard electrical safety practices and codes should must be fixed. (See errors on page 21) be used when working with a heater. Refer to the The air switch is also checked on power up. National Electric Code Standard Handbook by The air switch must indicate no airflow.

  • Page 14: Normal Operating Displays With Heater Not Running

    Normal Operating Displays With Heater Not Running The main display shows the plenum temperature. If or any other error condition will cause the display the dryer has not been running, the display should to show the limit or error condition. show outside temperature.

  • Page 15: Starting The Dryer

    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 air- flow alarm to go off when the start switch is depressed. The airflow alarm is simply the entire display going blank, and the "NO AIRFLOW"...
  • Page 16 16. When the burner ignites the display should read 19. Open or close the low cycle ball valve until "HI-FLAME " at the left of the display. Loosen the gas pressure is 3-5 lbs. for LP, or 1-2 lbs. the nut on the main regulator and turn screw in, to for natural gas.

  • Page 17: Btu's Per Gauge Pressure (Psi) 10-15 Hp Models (Approximate)

    10-15 hp Units BTUs Per Gauge Pressure (psi) PROPANE MODELS (Approximate) High Temperature 10-15hp 7/32" (0.219") Orifice OPERATING PRESSURE (psi) 816,013 1,148,640 1,409,477 1,632,026 1,825,859 1,995,762 2,153,700 2,227,883 MODELS Gauge Pressure (psi) Required to Maintain Temperature (Approximate) (10-15 hp High Temperature Propane Units Only) Heat Rise (°F) Static Model...

  • Page 18: Btu's Per Gauge Pressure (Psi) 20-40 Hp Models (Approximate)

    20-40 hp Units BTUs Per Gauge Pressure (psi) PROPANE MODELS (Approximate) High Temperature 20-40hp 5/16" (0.313") Orifice OPERATING PRESSURE (psi) 1,663,135 2,345,140 2,878,779 3,328,663 3,721,115 4,068,100 4,393,548 4,541,914 MODELS Gauge Pressure (psi) Required to Maintain Temperature (Approximate) (20-40 hp High Temperature Propane Units Only) Heat Rise (°F) Static Model...
  • Page 19 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) 1,597,824 2,266,320 2,770,656 3,195,648 3,573,216 3,919,776 4,234,416 MODELS Gauge Pressure (psi) Required to Maintain Temperature (Approximate) (20-40 hp High Temperature Natural Gas Units Only) Heat Rise (°F) Static Model...

  • Page 20: Btu's Per Gauge Pressure (Psi) Lo-Temp Models (Approximate)

    Lo-Temp Units BTUs Per Gauge Pressure (psi) PROPANE MODELS (Approximate) Low Temperature All hp 7/64" (0.109") Orifice OPERATING PRESSURE (psi) 203,405 287,160 351,771 409,203 457,063 497,744 538,425 555,176 MODELS Lo-Temp Units BTUs Per Gauge Pressure (psi) NATURAL GAS MODELS (Approximate) Low Temperature All hp 5/32"...

  • Page 21: Adjusting The Air Pressure Switch

    Adjusting the Air Pressure Switch Air pressure switch must be adjusted so "airflow". that it will activate with lowest level of grain that will be dryed in bin. If display does not read "airflow" remove cap from adjustment port and slowly turn Put grain in bin to level desired (low).

  • Page 22: Adjusting The Vaporizor

    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 adjust- ment bracket. 3. Swivel vaporizer away from flame if running too hot, closer to flame if too cold. 4.

  • Page 23: Programming Set Points

    The limits are continuously Multiple heaters may be done at any heater control console. The informa- checked during the drying operation. tion programmed is automatically transmitted to all other heaters when the A limit switch open or any other er- programming is complete.

  • Page 24: Programming Hours To Shutdown

    down arrow switches to alter the On hi-lo units when the unit reaches cycle set point, the flame will hours. Setting range is 0 to 200 switch to lo-flame and unit will not cycle back to hi-flame until (Set hours. Point minus Temperature Differential) is reached.

  • Page 25: Modulating Valve Operation

    Modulating Valve Operation 1. The modulating valve regulates gas flow through Wait until temperature under bin has equalized as the heater based on sensing unit in the plenum, before. If temperature under bin is less than the and maintains a constant drying air temperature. desired temperature, continue turning T-handle in, increasing gas flow and waiting for plenum 2.

  • Page 26: Factory Configuration

    Configuration Dip Multiple heaters connected together through the serial link. Switches (Normally Done Master with one Slave #1-dip switch At GSI) slave-dip switch 7 one and three on/all These switches are used to config- on/all others off. others off. ure the heater control for various types of heaters.

  • Page 27: Error Conditions

    Limit Switches The following limit switch errors light up individually on the heaters "SLA" on the main display LCD screen: PLENUM, HOUSING, VAPOR, TEMP HI LIMIT. and the "RX" "TX" symbols will be flashing. 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 If a limit switch error or one of arrow switch (up to 218 Hours).

  • Page 28: Series 2000 Heater Service

    Inspect and tighten all loose terminal con- All Airstream heaters are constructed of durable nections. Replace any damaged wiring. weather-resistant materials, so a minimum amount of service should be required; however 2. Remove burner orifice tube and inspect for dirt before the unit is started for the first time each season there are a few items that need to be or foreign material.

  • Page 29: Series 2000 Wiring Diagram

    WIRING DIAGRAM Series 2000 Downwind Heater...

  • Page 30: Series 2000 Heater Parts

    10-15 Dw High Temp Heater Parts 1 HF-7076 10-15 HP Housing Assembly 2 HF-7288 Access Side Cover 3 HF-7380 Plastic View Window 4 HF-7379 Access Panel Cover Plate 5 HF-7287 Access Panel Holders 6 HF-7063 10-15 Diverter Plate 7 CD-0238 Ignitor (2 Required) 8 HF-7201 Ignitor Clamp Half (2 Required)

  • Page 31: 10-15Hp Dw Low Temp Heater

    10-15 Dw Low Temp Heater Parts 1 HF-7076 10-15 HP Housing Assembly 2 HF-7288 Access Side Cover 3 HF-7380 Plastic View Window 4 HF-7379 Access Panel Cover Plate 5 HF-7287 Access Panel Holders 6 HF-7063 10-15 Diverter Plate 7 CD-0238 Ignitor (2 Required) 8 HF-7201 Ignitor Clamp Half (2 Required)

  • Page 32: 20-30Hp Dw High Temp Heater

    20-30 Dw High Temp Heater Parts 1 HF-7077 20-30 HP Housing Assembly 2 HF-7288 Access Side Cover 3 HF-7380 Plastic View Window 4 HF-7379 Access Panel Cover Plate 5 HF-7287 Access Panel Holders 6 HF-7064 20-30 Diverter Plate 7 CD-0238 Ignitor (2 Required) 8 HF-7201 Ignitor Clamp Half (2 Required)

  • Page 33: 20-30Hp Dw Low Temp Heater

    20-30 Dw Low Temp Heater Parts 1 HF-7077 20-30 HP Housing Assembly 2 HF-7288 Access Side Cover 3 HH-2020 Plastic View Window 4 HF-6914 Access Cover Plate 5 HF-7287 Access Panel Holders 6 HF-7064 20-30 Diverter Plate 7 CD-0238 Ignitor (2 Required) 8 HF-7201 Ignitor Clamp Half (2 Required) 9 HF-7204...

  • Page 34: 40Hp Dw High Temp Heater

    40hp Dw High Temp Heater Parts 1 HF-7472 40 HP Housing Assembly 2 HF-7288 Access Side Cover 3 HF-7380 Plastic View Window 4 HF-7379 Access Panel Cover Plate 5 HF-7287 Access Panel Holders 6 HF-7140 40 HP Diverter Plate 7 CD-0238 Ignitor (2 Required) 8 HF-7201 Ignitor Clamp Half (2 Required)

  • Page 35: 40Hp Dw Low Temp Heater

    40hp Dw Low Temp Heater Parts 1 HF-7472 40 HP Housing Assembly 2 HF-7288 Access Side Cover 3 HH-2020 Plastic View Window 4 HF-6914 Access Cover Plate 5 HF-7287 Access Panel Holders 6 HF-7140 40 Diverter Plate 7 CD-0238 Ignitor (2 Required) 8 HF-7201 Ignitor Clamp Half (2 Required) 9 HF-7204...

  • Page 36: Dw Heater Control Box

    Series 2000 DW Gas Heater Control Box Parts Part Number Description HF-7316 Control Box Housing (Series 2000) *HF-7276RH *Series 2000 rebuilt board assembly (w/decal) HF-7276H Series 2000 board assembly (w/decal) HH-1442 Toggle Switch HF-7277 Switch Boot HF-7255 Ballast Resistor HH-1093...

  • Page 37: Air Switch Temperature Sensor Box

    Air Switch Temperature Sensor Box Key Part Number Description LBS. KGS. 1 HF-7414 Recessed Plastic Plug 0.10 0.05 $0.05 2 DC-1103 Adjustment Decal 0.02 0.01 $1.10 3 HF-7461 Box Lid 0.88 0.40 $2.10 4 HH-7063 Air Pressure Switch 1.00 0.45 $36.00 5 HF-7236 Thermistor Temp Sensor...

  • Page 38: Dw Propane Vapor Pipetrain

    Dw Propane Vapor Pipetrain Parts 1 TFC-0023 1/2" 0-30 PSI Regulator (Deluxe, Sr 2000) 2 HH-3670 1/2" x 2 1/2" Nipple 3 TFC-0032 1/2" Solenoid (Deluxe, Sr. 2000) 4 HH-2029 1/2" x 1 1/2" Nipple 5 S-3853 1/2" x 1/4" x 1/2" Tee 6 HH-2984 30 PSI gauge 7 HH-2653...

  • Page 39: Dw Natural Gas Pipetrain

    Dw Natural Gas Vapor Pipetrain Parts 1 TFC-0051 3/4" Ball Valve 2 THH-4136 3/4" x 3" Nipple 3 TFC-0081 3/4" Solenoid (Deluxe, Sr 2000) 4 THH-4121 3/4" Close Nipple 5 THH-4158 3/4" x 1/4" x 3/4" Tee 6 D08-0022 15 PSI Gauge 7 D67-0008 3/4"...

  • Page 40: Dw Propane Vapor Hi-Lo Pipetrain

    Dw Propane Vapor Hi-lo Pipetrain Parts 1 TFC-0023 1/2" 0-30 PSI Regulator (Deluxe, Sr 2000) 2 HH-3670 1/2" x 2 1/2" Nipple 3 TFC-0032 1/2" Solenoid (Deluxe, Sr 2000) 4 HH-2029 1/2" x 1 1/2" Nipple 5 HH-1453 1/2" x 1/2" x 1/2" Tee 6 THH-4067 1/2"...

  • Page 41: Dw Natural Gas Hi-Lo Pipetrain

    Dw Natural Gas Hi-lo Pipetrain Parts 1 TFC-0051 3/4" Ball Valve 2 THH-4136 3/4" x 3" Nipple 3 TFC-0081 3/4" Solenoid (Deluxe, Sr 2000) 4 THH-4121 3/4" Close Nipple 5 THH-4174 3/4" x 3/4" x 1/2" Tee 6 THH-4066 3/4" Street Elbow 7 THH-4068 3/4"...

  • Page 42: Dw Lp Pipetrain

    Dw Lp Pipetrain Parts 1 HH-1251 1/2" Strainer 2 D07-0019 1/2" x 1 1/2" Nipple Sh. 80 3 TFC-0030 1/2" Ball Valve 4 HH-4845 1/4" Relief Valve 5 TFC-0092 1/2" Solenoid Valve 300 PSI 6 THH-4023 1/2" x 1/4" Reducer Bushing 7 THH-4058 1/2"...
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  • Page 44: Warranty

    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.
  • Page 45 1004 E. Illinois St. Assumption, IL 62510 Phone 217-226-4421 Fax 217-226-4498 August 1999...

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