GSI PNEG-012 User Manual
PNEG-012
Vane Axial Heater
Installation and Operation
Model #:
Owner ’s Manual
PNEG-012
Date: 05-31-13
Heater Check List
1. All wire connections
2. Spark plug gap 0.125
3. Pipe train tightness and gas leaks
4. Flame sensor tight
5. Fuse in place, extra fuse provided
6. Time delay reset
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. Modulating valve holds temperature within 1° (mod units only).
16. All decals and serial number tag
17. Aesthetic appearance
18. Manual
Tester Signature:___________________________
Date: ____________________________________
2 PNEG-012 Vane Axial Heater
Table of Contents
Contents
Chapter 1 Safety ..................................................................................................................................................... 4
Safety Guidelines .................................................................................................................................. 4
Introduction ........................................................................................................................................... 5
Chapter 2 Safety Decals ........................................................................................................................................ 6
Roof Damage Warning and Disclaimer ................................................................................................. 6
Heater Access Door Decals .................................................................................................................. 7
Control Box Decals ............................................................................................................................... 8
Chapter 3 Specifications ....................................................................................................................................... 9
Heater Specifications ............................................................................................................................ 9
Chapter 4 Installation .......................................................................................................................................... 10
Fuel Connection .................................................................................................................................. 10
Liquid Propane Models .......................... ... ... .... ... ... ... .... ... ... ... .... ......................................... .......... ... ... 10
Propane Vapor Models ....................................................................................................................... 10
Natural Gas Models ............................................................................................................................ 10
Standard Heater Electrical Installation .......................... ... ... ... .... ... ... ... ... ............................................. 10
Standard Heater - Second Heater Installation .............................. ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ... 12
Deluxe Heater Electrical Installation ................................................................................................... 13
Deluxe Heater - Second Heater Installation ........................................................................................ 14
Bin Configuration ................................................................................................................................. 15
Transition High-Limit Installation ......................................................................................................... 15
Plenum Thermostat Mounting ............................................................................................................. 16
Heater Orifice Setup ............................................................................................................................ 17
Chapter 5 Operation ............................................................................................................................................ 18
Operating Temperature Table .......................... ... ... ... .... ... ... ... .......................................... ... .... ... ... ... ... 18
Cycling Heater Operation .................................................................................................................... 18
Time Delay Operation - Standard Heater ............................................................................................ 19
High-Low Heater Operation ......................... .... ... .......................................... ... ... .... ... ......................... 20
Modulating Valve Operation .......................................................................................................... ... ... 21
Adjusting the Vaporizer ................................................................................................................. ... ... 22
BTUs per Gauge Pressure (PSI) - Propane Models (Approximate) ........................... ................... ...... 23
BTUs per Gauge Pressure (PSI) - Natural Gas Models (Approximate) ........................ ... ... .... ... ... ... ... 24
Chapter 6 Service ................................................................................................................................................. 25
Chapter 7 Troubleshooting - Standard Heater .................................................................................................. 26
Chapter 8 Wiring Diagrams ................................................................................................................................. 27
Standard Heater Wiring ....................................................................................................................... 27
Standard Heater Schematic ................................................................................................................ 28
Deluxe Heater ........ ... .......................................... ... .......................................... ... ................................ 29
Chapter 9 Parts List ............................................................................................................................................. 30
Standard Heater Control Box Parts ..................... ... ... .... ... ... ... .... ... ... ... ... .... ......................................... 30
Deluxe Heater Control Box Parts ........................................................................................................ 32
18" Gas Heater Parts ................... .... .......................................... ... ................................................ ...... 33
24", 26" and 28" Gas Heater Parts ...................................................................................................... 34
18" Vapor/NG Pipe Train Assembly .......... ... .... ... ... .......................................... ... .... ... ... ... ... .... ... ......... 36
24", 26" and 28" LP Pipe Train Assembly ........................................................................................... 37
24", 26" and 28" LP High-Low Pipe Train Assembly ........... ... .... ... ... ... ... ....................................... ... ... 38
24", 26" and 28" LP Modulating Pipe Train Assembly ........................................................................ 39
24", 26" and 28" Vapor/NG Pipe Train Assembly ............................................................................... 40
24", 26" and 28" Vapor/NG High-Low Pipe Train Assembly ............................................................... 41
24", 26" and 28" Vapor/NG Modulating Pipe Train Assembly ............................................................. 42
LP Supply Pipe Train Assembly .......................................................................................................... 43
Chapter 10 Warranty ............................................................................................................................................ 45
PNEG-012 Vane Axial Heater 3
1. Safety
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to
personal injury.
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
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. Failure to read this manual and its
safety instructions is a misuse of the equipment and may lead to serious injury or death.
DANGER
WARNING
CAUTION
NOTICE
4 PNEG-012 Vane Axial Heater
1. Safety
Introduction
Thank you for choosing a GSI product. It is designed to give excellent performance and service for
many years.
This manual describes the operation of the Deluxe and Standard Va ne Axial Heater: VHD and VHS . It is
designed for low to medium temperature grain conditioning, and is ideal for the aeration of rice, popcorn
or other select grains. It is available in both propane vapor and natural gas models.
Our foremost concern is your safety and the safety of others associated with this 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.
As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions
exist, and to inform all personnel associated with the equipment or in the area. Safety precautions may be
required from the personnel. Avoid any alterations to the equipment. Such alterations may produce a very
dangerous situation where SERIOUS INJURY or DEATH may occur.
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.
PNEG-012 Vane Axial Heater 5
2. Safety Decals
Excessive vacuum (or pressure) may
damage roof. Use positive aeration
system. Make sure all roof vents are
open and unobstructed. Start roof
fans when supply fans are started.
Do not operate when conditions exist
that may cause roof vent icing.
DC-969
CAUTION
GSI Group, Inc. 217-226-4421
If a decal is damaged or missing, contact:
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 1-217-226-4421
A free replacement will be sent to you.
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 reco mmend
the use of downward flow systems (suction). Severe roof damage can result from any block age of
air passages. Running fans during high humidity/cold weather conditions can cause air exhaust
or intake ports to freeze.
6 PNEG-012 Vane Axial Heater
Heater Access Door Decals
Stay clear of rotating
blade. Blade could start
automatically. Can cause
serious injury. Disconnect
power before servicing.
DC-1225
GSI Group 217-226-4421
WARNING
Flame and pressure beyond
door. Do not operate with
service door removed. Keep
head and hands clear. Can
cause serious injury.
DC-1227
WARNING
GSI Group 217-226-4421
Decal: DC-1225
Size: 4-7/8" x 2-1/4"
Located above access door on
heater housing.
NOTE: May be substituted with DC-1559 combination decals.
Decal: DC-1227
Size: 4-7/8" x 2-1/4"
Located above access door on
heater housing.
Decal: DC-113
Size: 4-3/4" x 1-5/8"
Located above access door on
heater housing.
See Note below.
See Note below.
2. Safety Decals
PNEG-012 Vane Axial Heater 7
2. Safety Decals
Decal: DC-889
Size: 2.813" x 1-3/8"
Located in control box on side
opposite switches.
DANGER
HIGH VOLTAGE
Will cause injury
or death.
Lockout power
before servicing.
DC-889
GSI Group Inc. 217-226-4421
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.
Remove plug to
reset high limit.
Enlevez le contact pour
reinitialiser la limite élévée.
DC-1165
DANGER
DC-535
Similar decal is incorporated into the
control panel decal.
Control Box Decals
8 PNEG-012 Vane Axial Heater
3. Specifications
Heater Specifications
Common Measurements
Fan Model 18" 24" 26" 28"
Inside Diameter (inches) 18-5/16" 24-1/4" 26-5/16" 28-1/8"
Bolt Circle Diameter (inches) 19-7/16" 25-3/4" 27-15/16" 29-5/8"
Length (inches) 22 22-1/2" 22-1/4" 25-1/4"
Weight (pounds) 83 129 133 136
Vapor Models
Fan Model 18" 24" 26" 28"
Minimum Operating Pressure (PSI) 2 2 2 2
Maximum Operating Pressure (PSI) 15 10 15 20
Minimum Supply Line (inches) 1/2" 3/4" 3/4" 3/4"
High Temperature Orifice (inches) 11/64" 7/32" 7/32" 7/32"
High Temperature BTU Rating at Maximum Pressure 1,400,000 2,100,000 2,700,000 3,000,000
High Temperature Fuel Flow at Maximum Pressure (CFH) 585 877 1128 1253
Low Temperature Orifice (inches) 3/32" 3/32" 3/32" 3/32"
Low Temperature BTU Rating at Maximum Pressure 400,000 350,000 400,000 500,000
Low Temperature Fuel Flow at Maximum Pressure (CFH) 167 146 167 208
Liquid Models
Fan Model 18" 24" 26" 28"
Minimum Operating Pressure (PSI) N/A 2 2 2
Maximum Operating Pressure (PSI) N/A 10 15 20
Minimum Supply Line (inches) N/A 3/8" 3/8" 3/8"
High Temperature Orifice (inches) N/A 7/32" 7/32" 7/32"
High Temperature BTU Rating at Maximum Pressure N/A 2,100,000 2,700,000 3,000,000
High Temperature Fuel Flow at Maximum Pressure (CFH) N/A 23 30 34
Low Temperature Orifice (inches) N/A 3/32" 3/32" 3/32"
Low Temperature BTU Rating at Maximum Pressure N/A 350,000 400,000 500,000
Low Temperature Fuel Flow at Maximum Pressure (CFH) N/A 4 4.5 5.5
Natural Gas
Fan Model 18" 24" 26" 28"
Minimum Operating Pressure (PSI) 1111
Maximum Operating Pressure (PSI) 7 4 5 7
Minimum Supply Line (inches) 3/4" 1" 1-1/4" 1-1/4"
High Temperature Orifice (inches) 17/64" 3/8" 3/8" 3/8"
High Temperature BTU Rating at Maximum Pressure 1,400,000 2,100,000 2,700,000 3,000,000
High Temperature Fuel Flow at Maximum Pressure (CFH) 1400 2100 2700 3000
Low Temperature Orifice (inches) 11/64" 7/32" 7/32" 7/32"
Low Temperature BTU Rating at Maximum Pressure 400,000 350,000 400,000 500,000
Low Temperature Fuel Flow at Maximum Pressure (CFH) 400 350 400 500
PNEG-012 Vane Axial Heater 9
4. Installation
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.
WARNING
Always disconnect and lock out power before working on or around heater.
Fuel Connection
WARNING
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. When using liquid
draw systems any moisture that may be present in tank or lines may freeze when system is used in
cold weather. To avoid this, the usual precaution is to purge the system with methanol.
2. Run proper size line (See Specifications on Page 9) to pipe train on heater. Have a qualified gas
service person inspect installation to be sure everything is installed according to local codes
and ordinances.
3. After installation is complete check all connections for leaks. Use liquid detergent or comparable
substance. Wear rubber gloves and eye protection. Avoid contact with liquid propane. DO NOT USE
FLAME FOR LEAK TESTING.
Propane Vapor Models
1. Propane vapor models are designed to run directly off of supply tank or from a separate
external vaporizer.
2. Run proper size line (See Specifications on Page 9) to pipe train on heater. Have a qualified gas
service person inspect installation to be sure everything is installed according to local codes
and ordinances.
3. After installation is complete check all connections for leaks.
Natural Gas Models
1. Natural gas models are similar to vapor models, but have a larger orifice to accommodate lower
pressure, sometimes found with natural gas.
2. Run proper size line (See Specifications on Page 9) to pipe train on heater. Have a qualified gas
service person inspect installation to be sure everything is installed according to local codes
and ordinances.
3. After installation is complete check all connections for leaks.
Standard Heater Electrical Installation
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.
10 PNEG-012 Vane Axial Heater
IMPORTANT: Heater must be interlocked with fan for safe operation.
Heater Power Connection
1. Connect power cord to fan control box.
2. Make field connections in fan box as shown in Figure 4A.
3. Connect deluxe thermostat control as shown in Figure 4A.
IMPORTANT: Thermostat must be installed for safe operation.
4. Installation
Figure 4A Heater Wiring Installation on a Fan Unit
PNEG-012 Vane Axial Heater 11
4. Installation
Standard Heater - Second Heater Installation
Two (2) standard 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 primary. The other heater (without the thermostat) will be referred to as
the secondary.
1. Install relay base (TD-100283) in primary heater control box.
2. Connect wire between terminal 13 on relay base to terminal 6 on terminal strip in primary heater.
3. Connect wire between terminal 14 on relay base to terminal 3 on terminal strip in primary heater.
4. Run two (2) wires (18 gauge) between primary and secondary heater.
5. Connect wires to terminals 5 and 9 (points A and B) on relay base in primary heater.
6. Connect wire from terminal 9 in primary to terminal 5 (point F) in secondary unit.
7. Connect wire from terminal 5 in primary to terminal 8 (point G) in secondary unit.
8. Install relay (TD-100282) in relay base.
Follow these additional steps for HIGH-LOW units.
1. Install relay base (TD-100283) in master heater control box.
2. Connect wire between terminal 13 (point E) on relay base to green wire from HIGH-LOW thermostat
in master unit. Do not disconnect other wires from green wire 3. Connect wire between terminal 14
on relay base to terminal 14 on other relay base in master heater.
3. Run two (2) wires (18 gauge) between master and slave heater.
4. Connect wires to terminals 5 and 9 (points C and D) on relay base in master heater.
5. Connect wire from terminal 9 in master to terminal 6 (point H) in slave unit.
6. Connect wire from terminal 5 in master to cycle solenoid and red light in slave unit. Do not connect
wire to side of cycle solenoid and light that are connected to terminal.
Figure 4B Standard Heater - Second Heater Relay Connection
12 PNEG-012 Vane Axial Heater
4. Installation
Always disconnect and lock out power before working on or around heater.
Deluxe Heater Electrical Installation
WARNING
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.
IMPORTANT: Heater must be interlocked with fan for safe operation.
Heater Power Connection
1. Connect power cord to fan control box.
2. Make field connections in fan box as shown in Figure 4C.
3. Connect deluxe thermostat control as shown in Figure 4C.
IMPORTANT: Thermostat must be installed for safe operation.
Figure 4C Illustration of deluxe Vane Axial Heater wiring installation on a fan unit.
PNEG-012 Vane Axial Heater 13
4. 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. Install relay base (TD-100283) in master heater control box.
2. Connect wire between terminal 6 on circuit board and terminal 14 on relay base in master heater.
3. Connect wire between terminal 13 on relay base and terminal 8 on circuit board in master heater.
4. Run two (2) wires (18 gauge) between master and slave heaters.
5. Connect wires to terminal 5 and 9 (points A and B) on relay base in master heater.
6. Connect wire from terminal 9 in master to terminal 14 (point F) in slave unit.
7. Connect wire from terminal 5 in master to terminal 15 (point E) in slave unit.
8. Install relay (TD-100282) in relay base.
Additional Steps for High-Low Units
1. Run two (2) wires (18 gauge) between master and slave unit.
2. Connect wires to terminals 21 and 22 (points C and D) on circuit board in main heater.
3. Connect wire from terminal 21 in master to terminal 12 (point H) in slave unit.
4. Connect wire from terminal 22 in master to terminal 13 (point G) in slave unit.
5. Install relay (TD-100282) in relay base.
Figure 4D The Control Board (HF-7318-1)
14 PNEG-012 Vane Axial Heater
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