GSI PNEG-584 User Manual

SERIES TWO HEATER
Neco Series Two
Centrifugal Heater
Installation And
MODEL # CHN - __ __ - __ __ - 2 __ (HIGH) MODEL # CLN - __ __ - __ __ - 2 __ (LOW)
Owner's Manual
MANUAL # PNEG-584
1
CHECK LIST
_____ 1. Check all wire connections _____ 2. Spark plug and flame sensor tightness set plug gap to 1/8" _____ 3. Check plug in terminal strips on back of circuit board to be sure they are plugged into proper
position. _____ 4. Software settings correct for type of heater (hi-low , on-off) _____ 5. Dip switch settings correct for heater model (slave, master) _____ 6. Most current software version installed _____ 7. Turn heater toggle switch on. Most current software version should be displayed first, fol
lowed by temperature. Screen should read "NO AIRFLOW". _____ 8. Turn fan on. Screen should read "AIRFLOW". _____ 9. Program hi-limit set point to 140 degrees F. _____ 10. Program cycle set point to 120 degrees F (only on hi-lo units). _____ 11. Program differential to 10 degrees F/ _____ 12. Turn gas on to heater unit. _____ 13. Press start switch on heater. Screen should flash "PURGE". _____ 14. After 10 second purge heater should light screen, and should read "HI-FLAME".
_____ 15. Adjust pressure to 10 psi (lp units) 5 psi (ng units). _____ 16. Check pipe train for leaks with soapy water. _____ 17. T emperature should rise to 120 degrees. Screen should read "LO-FLAME" and unit
_____ 18. Adjust pressure with ball valve to 2 psi (lp units) 1 psi (ng units). (hi-lo units only) _____ 19. On standard units temperature will rise to 140 degrees. Screen will read "OFF-CYCLE".
Heater will shut off at this point. _____ 20. Temperature will drop 10 degrees and unit will cycle back to hi-flame. Screen should read
"HI-FLAME". _____ 21. Observe unit go through 3 cycles. _____ 22. Pull wire off of housing hi-limit switch. Screen should read "ERROR 000" and "HOUSING
TEMP HI-LIMIT". Heater should shut down and lock out. Fan should shut off. _____ 23. Turn heater toggle switch on. Most current software version should be displayed first,
_____ 24. Turn fan on. Screen should read "AIRFLOW". _____ 25. Press start switch on heater. Screen should flash "PURGE". _____ 26. After 10 second purge heater should light. Screen should read "HI-FLAME". "FLAME" should
_____ 27. Shut gas off to heater and allow gas to burn out of system. _____ 28. 2-4 seconds after flame goes out on heater, "FLAME" in lower right hand corner of screen
should go out. Unit should begin to spark. _____ 29. After 10 seconds fan and heater should shut down and lock out. Screen should read
_____ 30. Check heater visually to see that all decals are in place and correctly located. _____ 31. Place owners manual in control box.
SERIES TWO HEATER
"FLAME" should appear on lower right hand corner of screen.
should cycle to lo-flame. (hi-lo units only)
followed by temperature. Screen should read "NO AIRFLOW".
appear on lower right hand corner of screen.
"ERROR 000" and "FLAME OUT".
Tester Signature___________________________________________ Date____________________________________
2
SERIES TWO HEATER
Warranty.......................................................................................................................4
Roof W arning, Operation & Safety .....................................................................................5
Safety Alert Decals.......................................................................................................6
Series T wo Heater Installation......................................................................................7
Centrifugal Heater Specifications...........................................................................7
Heater Dimensional Specifications........................................................................7
Plenum T emperature Sensor Mounting.................................................................8
Transition Hi-Limit Installation................................................................................8
Heater Unit W iring..................................................................................................9
Secondary Heater Unit Wiring................................................................................9
Machine T o Earth Ground.....................................................................................10
Proper Installation Of The Ground Rod.................................................................10
Previously Installed Units......................................................................................10
Fuel Connection For Liquid Propane Models.........................................................11
Fuel Connection For Propane V apor Models........................................................1 1
Fuel Connection For Natural Gas Models............................................................11
Series T wo Heater Operating Procedure.........................................................................12
Power Up..............................................................................................................12
Normal Operating Displays With Heater Not Running..........................................13
Starting The Dryer.................................................................................................14
Setting Gas Pressure ............................................................................................14
BTU's Per Gauge Pressure (PSI) Propane Models (Approximate)......................15
BTU's Per Gauge Pressure (PSI) Natural Gas Models (Approximate).................16
Adjusting The V aporizor ........................................................................................17
Programming Set Points.......................................................................................18
Programming Hours T o Shut Down.......................................................................19
Drying Grain In The Hours T o Shut Down Mode...................................................19
Run Hours Display...............................................................................................19
Multiple Heater Notes............................................................................................19
Factory Configuration..................................................................................................20
Configuration Dip Switches (Normally Done At GSI)............................................20
Error Conditions..........................................................................................................21
Limit Switches......................................................................................................21
Multiple Heater Error Conditions...........................................................................21
Misc Error Numbers..............................................................................................21
Series T wo Heater Service..........................................................................................22
Series T wo Heater Wiring..........................................................................................23
Notes...........................................................................................................................24
T ABLE OF CONTENTS
TABLE OF CONTENTS
3
ROOF WARNING AND DISCLAIMER
Roof Damage Warning And Disclaimer
GSI DOES NOT WARRANT ANY ROOF DAMAGE CAUSED BY EXCESSIVE V ACUUM OR INTERNAL PRESSURE FROM F ANS OR OTHER AIR MOVING SYSTEMS. ADEQUA TE VEN­TILA TION 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 RESUL T FROM ANY BLOCKAGE OF AIR P ASSAGES. RUN­NING F ANS DURING HIGH HUMIDITY/COLD WEATHER CONDITIONS CAN CAUSE AIR EXHAUST OR INT AKE PORTS
SERIES TWO HEATER
HEATER OPERATION
Thank you for choosing a Neco product. It is designed to give excellent performance and service for many years.
This manual describes the operation of the Neco Series Two Heater. 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.
The principal concern of Neco is your safety and the safety of others associated with grain handling equipment. This manual is written to help you under-
SAFETY ALERT SYMBOL
The symbol shown is used to call your attention to instructions con­cerning your personal safety . W atch for this symbol; it points out impor­tant safety precautions. It means "ATTENTION", "WARNING", "CAUTION", and "DANGER". Read the message and be cautious to the possibility of personal injury or death.
4
stand safe operating procedures, and some of the prob­lems that may be encountered by the operator or 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 who are in the dryer area. Avoid any alterations to the equipment. Such alterations may produce a very dangerous situation, where serious injury or death may occur.
WARNING! BE ALERT!
Personnel operating or working around electric fans should read this manual. This manual must be delivered with the equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment.
SERIES TWO HEATER
SAFTY ALERT DECALS
IMPOR TANT: Safety decals should be read and understood by all people in the grain handlng area. The bottom right decal should be present on the inside bin door cover and the roof manway cover. If a decal is damaged or is missing contact:
5
SAFTY ALERT DECALS
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. W e 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 inform all personnel associated with, or in the area of the Fill/Feed System. Safety pre­cautions may be required from the personnel. A void any alteration to the equipment. Such alterations may produce a very dangerous situation, where serious injury or death may occur .
SERIES TWO HEATER
CAUTION
CAUTION used without the safety alert symbol indi­cates a potentially hazardous situation which, if not avoided, may result in property damage.
BE ALERT!
Danger!
Personnel operating or work­ing around electrical equip-
ment should read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment.
This product is intended for the use of con­veying feed only . Any other use is a misuse of the product!
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.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious in­jury
WARNING
WARNING indicates a potentially hazardous situation which , if not avoided, could result in death or serious injury.
CAUTION
This product has sharp edges! These sharp edges may cause serious injury . To avoid injury handle sharp edges with caution and use proper protective clothing and equipment at all times.
The GSI Group Inc. recommends that you contact your local power company and have a repre­sentative review your installation so your wiring will be compatible with their system and so that you will have adequate power supplied to your unit.
The Chain Disk drive unit weights 159 lbs (72kg). All precautions should be taken when lifting and/or moving. Use at least two men when moving the unit anywhere.
The safety pages that follow are to show you where you can find the safety decals. The photo­graphs show exactly where the decals should be. If a decal has been damaged or is missing contact The GSI Group, Inc. for a free replacement.
CAUTION indicates a potentially hazardous situa­tion which, ifnot avoided, may result in minor or moderate injury .
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SERIES TWO HEATER
CENTRIFUGAL HEATER SPECIFICATIONS
HEATER INST ALLATION
All models
Liquid models
Vapor models
Natural gas
models
Hi-Temp Model
BTU rating
Weight
Maximum fuel flow (GPH)
Orifice size
Minimum operating pressure
Maximum operating pressure
Minimum line size
Maximum fuel flow (CFH)
Orifice size
Minimum operating pressure
Maximum operating pressure
Minimum line size
Maximum fuel flow (CFH)
Orifice size
Minimum operating pressure
Maximum operating pressure
Minimum line size
4000000
145
43
.25
3
30
3/8"
1590
.25
2
30
1"
4200
.375
1
15
1.1/4"
HEATER DIMENSIONAL SPECIFICATIONS
Lo-Temp Model
500000
135 N/A
N/A N/A N/A N/A
210
.109
1
15
1/2" 500
.156
1 7
1"
Heater Size
Inside Height
Inside Width Inside length
10-15
30.1/4"
19.1/2" 24"
20-30
33.1/4"
21.3/4" 24"
40
33.1/4"
23.11/16" 24"
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HEATER INST ALLATION
PLENUM TEMPERA TURE
SENSOR MOUNTING
The plenum temperature sensor is the white PVC junction box with bolt extending from outside attached by a cord to the fan/heater control box.
1. 24" to the right side of the transi­tion, drill one 3/8" hole in the cen­ter of the plenum in a valley on the bin sidewall.
2. Insert the probe through the hole.
3. Position the housing so that the tabs are vertical, and the cord exits the housing horizontally.
SERIES TWO HEATER
4. Use two self drilling screws to mount the housing to the bin sidewall.
5. Caulk between the housing and the sidewall to seal.
TRANSITION HI-LIMIT INSTALLATION
1. Mark location on transition one (1) 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 hi-limit using supplied self drilling screws.
Plenum temperature sensor installation.
Figure 1: The transition connecting the heater to the bin with the plenum
thermostat in place.
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SERIES TWO HEATER
WIRING
HEA TER UNIT
1. Be sure fan unit is installed and wired to meet local codes. Be sure equipment is well grounded (see page 9).
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 S-wire black cord from heater unit to fan unit and secure to fan.
HEATER INST ALLATION
4. Orange and red wires should be connected in series with coil in fan. When contacts in heater between these wires open fan shuts down. Recommended wiring is shown in Figure 2.
5. Black and white wires should be connected to a fused
Figure 2: Wiring diagram for the fan and heater unit.
120V power supply as shown. Green wire should be con­nected to ground in fan.
Figure 3: Secondary heater wiring diagram.
SECONDARY
HEA TER UNIT
1. Secondary heater unit runs as a slave of heater unit #1 and re-quires no plenum or grain temperature sensor.
2. Run (2) 20 gauge (minimum) wires from secondary heater unit (slave) to heater unit #1 (master).
3.
Connect wires as shown in Figure 3.
4. Third heater unit may also be added to system. If adding third unit, run connections to master unit #1 and connect them inparallel with secondary heater unit.
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HEATER INST ALLATION
SERIES TWO HEATER
Transformer and Wiring Voltage DropPower Supply
An adequate power supply and proper wiring are important factors for maximum performance and long life of the dryer . Electrical service must be adequate enough to prevent low voltage damage to motors and control circuits (see Electrical Load Informationon page
40) In 220V 1 ph and 220V 3 ph systems a sepa-
rate neutral wire is required for the 120V heater circuit, and should be connected to terminal #1 in the master heater . Do not run in conduit with mo­tor power lines.
Machine To Earth Grounding
It is very important that a Machine T o Earth ground be installed at the worksite. The complete unit must be wired and grounded to all local applicable codes. The proper grounding will provide safty to the operators and ensure long life to all circuit boards.
It is necessary to know the distance from the unit to the available transformer, and the horsepower of your fan unit. Advise the service representative of your local power supplier that an additional load will be placed on the line. Each fan motor should be wired through a fused or circuit breaker disconnect switch. Check the KVA rating of the transformers, considering horsepower and load. The power supply wiring , main switch equipment and transformers must provide adequate motor start­ing and operating voltage. Voltage drop during startup should not exceed 14% of normal voltage, and after motor is running at full speed it should be within 8% of normal voltage. Check Electrical Load Information for HP ratings and maximum amp loads to properly size wire and fusing elements. Standard electrical safty prac­tices and codes should be used. (Refer to National Elec­trical Code)
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SERIES TWO HEATER
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.
HEATER INST ALLATION
IMPORTANT! Do not use propane tanks that have previously been used for ammonia unless they have been purged according to procedures of the Na­tional L.P . Association.
Fuel supply system must comply with local codes
for L.P . gas installation.
FUEL CONNECTION
LIQUID PROP ANE
MODELS
1. L.P. models are designed to run on liquid propane with liquid draw from the propane tank. Avoid using propane supply tanks that have been used 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 situation, purge the system with methanol.
2. Run proper size line (see specification on page 6) to liquid pipe train on heater. Have a qualified gas ser vice person inspect installation to be sure that every thing is installed according to local codes and ordi nances.
3. After installation is complete check all connections for leaks with liquid detergent or comparable. Wear rubber gloves and eye protection. A void contact with liquid propane. DO NOT USE FLAME FOR LEAK TESTING.
AL WAYS DISCONNECT AND LOCK OUT
POWER
BEFORE WORKING ON OR AROUND
HEATER
PROP ANE VAPOR
MODELS
1. Propane vapor models are designed to run directly off of a supply tank or from a separate external va porizer.
2. Run proper size line (see specifications on page 6) to pipe train on heater. Have a qualified gas service person inspect installation to be sure that everything is installed according to local codes and ordinances.
3. After installation is complete check all connections for leaks. DO NOT USE FLAME FOR LEAK TESTING.
NATURAL GAS MODELS
1. Natural gas models are designed to run directly off of a supply tank or from a separate external vapor izer.
2. Run proper size line (see specification on page 6) 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. DO NOT USE FLAME FOR LEAK TESTING.
11
HEATER OPOERA TION PROCEDURE
SERIES TWO HEATER
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 elec-
trician should make all wiring installations.
POWER UP
All safety and high limit switches are checked upon power up. If a safety or limit is open, the control displays it. The control cannot operate with a safety switch error, and the fan cannot turn on with an error condition. There is no way to bypass an error condition. It must be fixed. (see errors on page 20)
The air switch is also checked on power up. The air switch must indicate no airflow . This is necessary to check the function of the air switch. However, if the opera-tor forgets and turns the fan on before the controller has been powered up, the controller locks
up with the main display alternating between a "FAN" and "ON" message. This may be bypassed by depress­ing and holding the "F AN BYPASS" switch (lower right switch). Normal operating procedure should be to power up the controller with the fan off.
If multiple heaters are tied together, and the mas­ter detects that the slave fan is on (the air switch stuck?), the master will lock up displaying "SLA ER­ROR". This condition may be bypassed with the "F AN BYPASS" switch.
ALWAYS DISCONNECT
AND LOCK OUT POWER
BEFORE WORKING ON OR
AROUND HEATER
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SERIES TWO HEATER
HEATER OPOERA TION PROCEDURE
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. its are continuously checked during the off mode. A limit switch open, or any other error condition will cause the display to show the limit or error condition. When drying
All safeties or high lim-
is not occurring, and the limit or error con­dition is corrected, the display returns to its normal
output. This is not the case with an error or limit con­dition during the drying operation. This causes the dis­play to lock up in the error display mode. This is to keep the display locked up with the condition illumi­nated. (see section on "Running the Dryer" for mode explanation on page 16)
The heater display with fan off ( no airflow).
13
HEATER OPOERA TION PROCEDURE
SERIES TWO HEATER
ST ARTING 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.
To start the dryer, just push the "ST ART" switch. The first message to come up will be the "PURGE" message--the drying process begins with a 10 second purge.
When multiple heaters are con­nected together, drying may be started from any heater control.
SETTING GAS PRESSURE
1. At heater turn toggle switch
to "ON" position.
2. Press the "PROGRAM TEM-
PERATURE" button.
3. Use the increase or decrease
button to set the "PLENUM
HIGH LIMIT SET POINT" to
desired setting (100°-160°*).
4. Press the "PROGRAM TEM-
PERA TURE" button to continue
to set the "CYCLE SET
POINT". (hi-lo units only)
5. Use the increase or decrease
buttons to set the "CYCLE SET
POINT" to desired setting
(90°-150°*) (hi-lo units only).
Programming the temperature
differential.
6. Press the "PROGRAM TEM­PERA TURE" button to continue to set the "TEMPERATURE DIFFERENTIAL".
7. Use the increase or decrease buttons to set the "TEMPERA­TURE DIFFERENTIAL" to 10°*.
8. Open all manual gas shut off valves, on and to the heater unit.
9. Start the fan unit.
10. Make sure that the blade is spin­ning in the right direction. If not place the toggle switch in the "OFF" position and correct the problem.
11. After the fan reaches full speed the display should read "AIR­FLOW" in the upper right hand corner.
12. Press the start button on the heater control.
13. After 10 seconds the burner should ignite. If not, turn "OFF" the toggle switch and then back "ON". Repeat 12-15.
14. When the burner ignites the dis-
play 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 gauge 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)
15. Press the "PROGRAM TEM­PERATURE" button to
change the high limit set point. Press i t again to change the "CYCLE SET POINT". (hi-lo units only)
16. Decrease the "CYCLE SET
POINT TEMPERATURE" until the heater cycles to low flame. (hi­lo units only)
17 . Open or close the low cycle ball
valve until the gas pressure is 3-5 lbs. for LP, or 1-2 lbs. for natural gas. (hi-lo units only)
18. Increase the cycle set point to
return to high flame. (hi-lo units only)
19. Watch heater run several min-
utes to make sure it cycles be­tween hi and lo flame or on and off properly .
20. Hi-flame pressure should be
adjusted so plenum reaches cy­cling temperature easily .
21. Adjust pressure on on/off units
so that unit is on approximately 75% of the time.
14
*Temperatures are fahrenheit.
SERIES TWO HEATER
HEATER OPOERA TION PROCEDURE
10 - 15 HP UNITS
BTU’s Per Gauge Pr essure (PSI)
PROPOANE MODELS
(Approximate)
HIGH TEMPERATURE 10-15hp 7/32" orifice
OPERATING PRESSURE (PSI)
246810121415 ALL MODELS 816013 1148640 1409477 1632026 1825859 1995762 2153700 2227883
Gauge Pressure (Psi) Required To Maintain Temperature ( Approximate )
( 10-15 Horsepower High Temp Propane Units Only )
Static
Fan Model Pressure 60 80 100 120 140 160 180
2"24681013
10HP 4" 1 3 5 6 8 11 14
6"11356810 2" 3 6 9 12 15
15HP 4" 3 5 7 10 13
6"235691114
Heat Rise De gr ee s F
BTU’s Per Gauge Pressur e (PSI)
NA TURAL GAS MODELS
(Approximate)
HIGH TEMPERA TURE 10-15hp 1 1/32” orifice
OPERA TING PRESSURE (PSI)
1234567 ALL MODELS 859104 1218432 1489296 1718208 1921584 2107632 2276352
Gauge Pressure (Psi) Required To Maintain Temperature ( Approximate )
( 10-15 Horsepower High Temp Natural Gas Units Only )
Static
Fan Model Pressure 60 80 100 120 140 160 180
2" 1 1.75 2.5 3.5 4.75 6
10HP 4" 0.75 1.25 2 2.75 3.75 4.75 6
6" 0.5 1 1.5 2 2.75 3.5 4.25 2" 1.5 2.5 3.75 5.5
15HP 4" 1.25 2 3 4.25 5.75
6" 0.75 1.25 2 2.75 3.75 5 6
Heat Rise De gr ee s F
15
HEATER OPOERA TION PROCEDURE
SERIES TWO HEATER
20 - 40 HP UNITS
BTU’ s Per Gauge Pressure (PSI) PROP ANE MODELS (Appr oximate)
HIGH TEMPERA TUR E 20-4 0hp 5/16" or ifice
OPERATING PRESSURE (PSI)
2 4 6 8 10 12 14 15 ALL MODELS 1663135 2345140 2878779 3328663 3721115 4068100 4393548 4541914
Gauge Pressure (Psi) Required To Maintain Temperature ( Approximate )
( 20-40 Horsepower High Temp Propane Units Only )
Static
Fan Model Pressure 60 80 100 120 140 160 180
2"22457810
20HP 4"1234578
6"1234567 2"235791215
25HP 4" 2 3 4 6 8 10 13
6"22456810 2"24681115
30HP 4" 2 4 5 7 10 13
6"234681013 2"36812
40HP 4" 3 5 7 11 14
6"347912
Heat Rise Degr ees F
BTU’s Per Gauge Pressur e (PSI) NA TURAL GAS MODELS (Approximate)
HIGH TEMPERA TURE 20-40hp 15/32” orifice
OPERA TING PRESSURE (PSI)
1234567 ALL MODELS 1597824 2266320 2770656 3195648 3573216 3919776 4234416
Gauge Pressure (Psi) Required To Maintain Temperature ( Approximate )
( 20-40 Horsepower High Temp Natural Gas Units Only )
Static
Fan Model Pressure 60 80 100 120 140 160 180
2" 0.75 1.25 1.75 2.5 3.25 4.25 5.5
20HP 4" 0.5 1 1.5 2 2.75 3.5 4.5
6" 0 .5 0.75 1.25 1.75 2.25 3 3.75 2" 1 1.75 2.25 3.5 4.75 6.25
25HP 4" 0.75 1.5 2.25 3.25 4 5.25 6.25
6" 0.5 1.25 1.75 2.5 3.25 4.25 5.5 2" 1.25 2 3 4.5 6
30HP 4" 1 1.75 2.75 3.75 5 7
6" 0.75 1.5 2.25 3 4 5.25 7 2" 1.75 3 4.5 6.25
40HP 4" 1.5 2.5 4 5.5
6" 1.25 2.25 3.5 4.75 6.75
Heat Rise Degr ees F
16
SERIES TWO HEATER
HEATER OPOERA TION PROCEDURE
Lo Temp Units
BTU’s Per Gauge Pr essure (PSI)
PROP ANE MODELS
(Approximate)
LOW TEMPERA TURE ALL HP’s 7/64” orifice
OPERA TING PRESSURE (PSI)
246810121415 ALL MODELS 203405 287160 351771 409203 457063 497744 538425 555176
BTU’s Per Gauge Pr essure (PSI)
NA TURAL GAS MODELS
(Approximate)
LOW TEMPERA TURE ALL HP’s 5/32” orifice
OPERA TING PRESSURE (PSI)
1234567 ALL MODELS 177840 251712 308256 355680 397632 435936 470592
17
HEATER OPOERA TION PROCEDURE
SERIES TWO HEATER
ADJUSTING THE
VAPORIZOR
1. V aporizer should be adjusted so the vapor pipe train runs warm to the touch (100°-120°F).
2. Loosen 5/16" bolts on adjust­ment bracket.
3. Raise vaporizer if running too hot, lower if too cold.
4. Move vaporizer only 1" at a time and allow a few minutes for temperature to equalize.
5. Tighten 5/16" bolts and watch heater run for several minutes to verify adjustment.
18
Adjusting the vaporizer coil on a liquid propane model.
The top photo shows the setting up (cool),
and the bottom photo shows the coil down (hot).
SERIES TWO HEATER
HEATER OPOERA TION PROCEDURE
The limits are continuously checked during the dry­ing operation. A limit switch open or any other error condition will cause the dryer to shut down, and the fan will be shutdown. If a limit opens, or an error condi-
tion 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. This is to keep the display locked up
with the condition that caused the error, allowing the opera­tor time to determine what caused the shutdown.
PROGRAMMING SET POINTS
Depressing the "PROGRAM" switch (lower left) causes the display to enter the program mode. Each item below is programmed by using the up and down arrow switches. Holding down these up and down arrow switches for about 2 seconds will cause the numbers to increase/de­crease rapidly until the switch is released. When fin­ished programming an item, depressing the "PROGRAM" switch again will cause the new setting to be entered into memory, and the display will advance to the next func­tion to be programmed.
Programming may be done at anytime (unless an error condi­tion exists) even while the dryer is in operation.
Programming a system with multiple heaters may be done at any
heater control console. The infor­mation programmed is automatically transmitted to all other heaters when the programming is complete.
Hi Limit Set Point--The upper left cursor is flashing indicating the mode. If the plenum temperature increases above this point, the flame is shut off--"OFF-CYCLE" is dis­played on screen.
Cycle Set Point--The upper 2nd from left cursor is flashing indicat-
ing the mode. If the dryer is not a hi-lo dryer, this function is skipped. If the plenum temperature increases above this point, the flame reduces to "LO-FLAME".
Humidity Set Point--The upper 2nd from right cur­sor is flashing indicating the mode. If the humidity is above this point the dryer operates normally--flame on and off at the high limit and cycle set points. If the hu­midity is below this point the dryer goes into the "OFF­CYCLE" mode. Note: At this time a true humidity
sensor has not been introduced. To use this option, set the humidity setting to 50% and use a humidistat switch. When the humidity is high the switch is closed,
indicating high humidity. At this setting, the dryer runs normally .
Temperature Differential--The upper right cursor is flashing indicating the mode. If the flame shuts off because the temperature is greater than the high limit set point, the temperature must fall below the (Set Point minus T empera­ture Differential) for the flame to come back on.
Programming the high-limit set point.
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HEATER OPOERA TION PROCEDURE
PROGRAMMING HOURS TO SHUT DOWN
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 T emperature 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. If the flame shuts off because the humidity must rise above the (Set Point plus Humid­ity Differential) for the flame to come back on.
the humidity is less than the humidity set point,
To change the hours to shut down, depress and hold the "SHUTDOWN HOURS" switch. While holding in on the switch, depress the up and down arrow switches to alter the hours. Setting range is 0 to 200 hours.
DRYING GRAIN IN THE HOURS TO SHUT
While drying grain, depress and hold the "SHUTDOWN HOURS" switch. While holding in on that switch, de­press the "START" switch. After depressing the start switch one time, the heater is in the shutdown mode. Then,
SERIES TWO HEATER
DOWN MODE
the fan and heater shut down when the time expires. This is indicated by the lower left cursor flashing.
Depressing the start switch again (while holding in on the "SHUT­DOWN HOURS" switch) will cause only the heater to shut off. This leaves the fan on when the time expires. This is indicated by the 2nd from lower left cursor flashing. Depressing the start switch one more time returns the heater into the continuous--non-shut­down mode.
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RUN HOURS DISPLA Y
Run hours are recorded when the controller detects that the fan is on (airflow). The hours may be viewed by depressing the "HOURS" to get hours and "HOURS X 1000" to get the number of 1000 hours accumu­lated.
MUL TIPLE HEATER NOTES
When multiple heaters are connected together, the temperature and humid­ity sensors must be connected to the master.
Setting the cycle set point.
SERIES TWO HEATER
F ACTORY CONFIGURATION
CONFIGURATION DIP
SWITCHES (NORMALLY
DONE AT FACTORY)
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.
Multiple heaters connected together through the serial link.
Master with one slave-dip switch 7 on/all others off.
Master with two slaves-dip switch 8 on/all others off.
Slave #1-dip switch one on/all others off.
Slave #2-dip switch two on/all others off.
Master with 3 slaves-dip switch 7 & 8 on/all others off.
Slave #3-dip switch one & two on/all others off.
The backside of the control board, showing the dip switch placement.
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ERROR CONDITIONS
SERIES TWO HEATER
LIMIT SWITCHES
The following limit switch errors light up individually on the heaters LCD screen: PLENUM, HOUSING, V A­POR, TEMP HI LIMIT.
Note: When a shutdown does oc­cur due to an error condition, the amount of time elapsed since the shut-
down can be viewed by pressing the down arrow switch (up to 218 hours).
MULTIPLE HEATER ERROR
CONDITIONS
If two or more heaters are connected together through the serial link, and the master cannot communicate with
a slave controller, the master will dis­play "SLA" on the main display and the "RX" "TX" symbols will be flashing.
If a limit switch error or one of the error numbers 1 through 8 occurs, that error is displayed on the slave where the error originates. The mas­ter displays "SLA ERROR".
MISC ERROR NUMBERS
1 2 3 4 5 6
Temperature probe 1 open.
7
Temperature probe 1 short.
8 9 10 11 12
Temperature probe 2 open.
Temperature probe 2 short.
Airflow open.
Airflow short.
Illegal flame sense.
Error 7 is most likely caused by stuck open solenoid. Error 7 will not shut down fan until loss of flame is detected by control.
13
+11 volt DC shorted to ground.
The heater
control display
showing error
000.
Flame probe short error.
000
This indicates that one of the other on screen errors (vapor, plenum or housing temp hi­limit or flame out or no airflow has occured.
Slave #1 inconsis­tent with master with either the drying grain flag or the LP main sole­noid or cycle sole­noid. Most likely the slave got reset powering up with the solenoids off.
(Errors 9 through 11 are displayed only if multiple heaters are tied together through serial link).
Note: Temperature sensor connection -the temperature sensor (bolt) must always be connected to the master.
Slave #2 inconsis­tent. Same as error 9 for slave #1.
Slave #3 inconsis­tent. Same as error 9 for slave #1.
Wrong voltage.
Dip switch #5 is the voltage selector switch. If dip switch #5 in "ON" that selects 240 VAC. If the unit has only 120 VAC applied, er­ror 12 will show up. If dip switch #5 is"OFF" that selects 120 VAC. If the unit has 240 VAC applied error 12 will show up.
This is im­portant because if the heater is set up at NECO for 120 VAC and the customer connects to 240 VAC the heater control will work, but if allowed to operate the solenoids will have 240 VAC ap­plied to them which will damage solenoids.
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SERIES TWO HEATER
HEATER SERVICE
All NECO heaters are constructed of durable weather­resistant 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. Inspect and tighten all loose terminal connections. Replace any damaged wiring.
2. Remove burner orifice tube and inspect for dirt or foreign material. Clean out if necessary.
3. Inspect burner for wear or foreign material in any of the ports. Clean or replace parts if necessary .
4. Inspect the spark plug and flame probe for corrosion and damage. Clean or replace if necessary.
The Series Two control box.
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HEATER WIRING
SERIES TWO HEATER
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SERIES TWO HEATER
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25
WARRANTY
NECO WARRANTS ALL PRODUCTS MANUFACTURED BY NECO 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. NECO'S ONLY OBLIGATION IS, AND PURCHASER'S SOLE REMEDY SHALL BE FOR NECO, TO REPAIR OR REPLACE, AT NECO'S OPTION AND EXPENSE, PRODUCTS THAT, IN NECO'S SOLE JUDGMENT, CONTAIN A MATERIAL DE­FECT DUE TO MATERIALS OR WORKMANSHIP. ALL DELIVERY AND SHIPMENT CHARGES TO AND FROM NECO'S FACTORY WILL BE PURCHASER'S RESPONSIBILITY. EXPENSES INCURRED BY OR ON BEHALF OF THE PURCHASER WITHOUT PRIOR WRITTEN AUTHORIZATION FROM AN AUTHORIZED EM­PLOYEE OF NECO SHALL BE THE SOLE RESPONSIBILITY OF THE PURCHASER.
EXCEPT FOR THE ABOVE STATED EXPRESS LIMITED WARRANTIES, NECO MAKES NO WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MER­CHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH (i) PROD­UCT MANUFACTURED OR SOLD BY NECO OR (ii) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR EMPLOYEE OF NECO REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR PUR­POSE, OR DESIGN OF SUCH PRODUCT OR PRODUCTS.
SERIES TWO HEATER
IN NO EVENT SHALL NECO BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL OR CONSE­QUENTIAL DAMAGES, INCLUDING, WITHOUT LIMITATION, LOSS OF ANTICIPATED PROFITS OR BEN­EFITS. PURCHASER'S SOLE AND EXCLUSIVE REMEDY SHALL BE LIMITED TO THAT STATED ABOVE, WHICH SHALL NOT EXCEED THE AMOUNT PAID FOR THE PRODUCT PURCHASED. THIS WARRANTY IS NOT TRANSFERABLE AND APPLIES ONLY TO THE ORIGINAL PURCHASER. NECO SHALL HAVE NO OBLIGATION OR RESPONSIBILITY FOR ANY REPRESENTATIVE OR WARRANTIES MADE BY OR ON BEHALF OF ANY DEALER, AGENT OR DISTRIBUTOR OF NECO.
NECO ASSUMES NO RESPONSIBILITY FOR FIELD MODIFICATIONS OR ERECTION DEFECTS WHICH CREATE STRUCTURAL OR STORAGE QUALITY PROBLEMS. MODIFICATIONS TO THE PRODUCT NOT SPECIFICALLY COVERED BY THE CONTENTS OF THIS MANUAL WILL NULLIFY ANY PRODUCT WAR­RANTY THAT MIGHT HAVE BEEN OTHERWISE AVAILABLE.
THE FOREGOING WARRANTY SHALL NOT COVER PRODUCTS OR PARTS WHICH HAVE BEEN DAMAGED BY NEGLIGENT USE, MISUSE, ALTERATION OR ACCIDENT. THIS WARRANTY COVERS ONLY PRODUCTS MANUFACTURED BY NECO. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED. NECO RESERVES THE RIGHT TO MAKE DESIGN OR SPECIFICATION CHANGES AT ANY TIME.
PRIOR TO INSTALLATION, PURCHASER HAS THE RESPONSIBILITY TO RESEARCH AND COMPLY WITH ALL FEDERAL, STATE AND LOCAL CODES WHICH MAY APPLY TO THE LOCATION AND INSTAL­LATION.
26
SERIES TWO HEATER
Neco
Box 12277, 9364 N. 45 St.
Omaha, Nebraska 68112
phone 402-453-6912
fax 402-453-0471
February 1999
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