GSI PNEG-591 User Manual
Series 2000 Downwind Heater
Downwind Series 2000
Centrifugal Heater
Installation And
Operating Instructions
MODEL # CH__ - __ __ - __ __ - 2 __ (HIGH)
MODEL # CL__ - __ __ - __ __ - 2 __ (LOW)
Owner's
Manual
PNEG-591
1
Series 2000 Downwind Heater
2
Series 2000 Downwind Heater
Safety ..........................................................................................................................4
Series 2000 Heater Installation.........................................................................................6
High T emperature Heater Specifications................................................................6
Low T emperature Heater Specifications................................................................6
Air Pressure Switch and T emperature Sensor Box......................................................7
Transition Hi-Limit Installation................................................................................7
Bin Configuration/Operating T emperature T able...................................................8
Heater Unit Wiring..................................................................................................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
Installing Optional Humidity Sensor ....................................................................12
Series 2000 Operating Procedure....................................................................................13
Power Up..............................................................................................................13
Normal Operating Displays With Heater Not Running..........................................14
Starting The Dryer.................................................................................................15
Setting Gas Pressure ............................................................................................15
BTU's Per Gauge Pressure (PSI) 10-15 hp Models (Approximate)......................17
BTU's Per Gauge Pressure (PSI) 20-40 hp Models (Approximate).....................18
BTU's Per Gauge Pressure (PSI) Lo-temp Models (Approximate).....................20
Adjusting the Air Pressure Switch.......................................................................21
Adjusting The V aporizor ........................................................................................22
Running The Dryer...............................................................................................22
Programming Set Points.......................................................................................23
Programming Hours T o Shutdown.......................................................................24
Drying Grain In The Hours T o Shutdown Mode...................................................24
Run Hours Display ...............................................................................................24
Multiple Heater Notes............................................................................................24
Modulating V alve Operation.................................................................................25
Factory Configuration..................................................................................................26
Configuration Dip Switches (Normally Done At GSI)............................................26
Error Conditions..........................................................................................................27
Limit Switches......................................................................................................27
Multiple Heater Error Conditions...........................................................................27
Misc Error Numbers..............................................................................................27
Series 2000 Heater Service..........................................................................................28
Series 2000 Wiring Diagram.........................................................................................29
Series 2000 Heater Parts............................................................................................30
10-15hp DW High T emp Heater ...............................................................................30
10-15hp DW Low T emp Heater................................................................................31
20-30hp DW High T emp Heater................................................................................32
20-30hp DW Low T emp Heater ...........................................................................33
40hp DW High Temp Heater...............................................................................34
40hp DW Low T emp Heater................................................................................35
DW Heater Control Box......................................................................................36
Air Switch T emperature Sensor Box.....................................................................37
DW Propane Vapor Pipetrain..............................................................................38
DW Natural Gas Pipetrain...................................................................................39
DW Propane Vapor Hi-Lo Pipetrain....................................................................40
DW Natural Gas Hi-Lo Pipetrain........................................................................41
DW LP Pipetrain.................................................................................................42
Warranty .......................................................................................................................44
TABLE OF CONTENTS
3
SAFETY
SAFETY FIRST
General Safety Statements
The GSI Group Inc’s Principal concern is
your safety and the safety of others associated with
grain handling equipment. We want to keep you
as a customer. This manual is to help you understand safe operating procedures and some problems which may be encountered by the operator
and other personnel.
Series 2000 Downwind Heater
CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, ma y result in minor or moder ate
injury .
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 product. Safety
precautions may be required from the personnel.
This product is ideal for the conditioning of corn,
soy beans or other select grains. A void any alteration to the equipment, such alterations may produce a very dangerous situation, where serious injury or death may occur.
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
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, ma y result in property damage.
If a decal is damaged or missing contact:
The GSI Group Inc.
1004 E. Illinois St.
Assumption, IL 62510
217-226-4421
A free replacement will be sent to you.
BE ALERT!
Danger!
Personnel operating or
working around electrical
equipment 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.
WARNING
WARNING indicates a potentially hazardous situation
which , if not avoided, could result in death or serious
injury .
4
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.
Series 2000 Downwind Heater
Roof Damage Warning And Disclaimer
SAFETY
GSI DOES NOT WARRANT ANY ROOF DAMAGE
CAUSED BY EXCESSIVE VACUUM OR INTERNAL PRESSURE FROM FANS OR OTHER AIR MOVING SYSTEMS.
ADEQUA TE VENTILATION AND/OR "MAKEUP AIR" DEVICES SHOULD BE PROVIDED FOR ALL POWERED AIR
HANDLING SYSTEMS. GSI DOES NOT RECOMMEND
THE USE OF DOWNW ARD FLOW SYSTEMS (SUCTION).
SEVERE ROOF DAMAGE CAN RESULT FROM ANY
BLOCKAGE OF AIR PASSAGES. RUNNING FANS DURING HIGH HUMIDITY/COLD WEATHER CONDITIONS
CAN CAUSE AIR EXHAUST OR INTAKE PORTS
5
SPECIFICATIONS
Series 2000 Downwind Heater
Centrifugal Heater Specifications
Hi-Temp Hi-Temp Lo-Temp Model
10-15HP 20-40HP All un its
All Models BTU Rating 2225000 4500000 500000
Weight 145 145 135
Liquid Models Maximum Fuel flow (GPH) 24 49 N/A
Orifice siz e 0.2188 0.3125 N/A
Mod Valve Bypass Orifice Blue Aluminum Yellow
Minimum operating pressure 1 1 N/A
Maximum operating pressure 15 15 N/A
Minimum lin e si ze 3/8" 3/8" N/A
Va por Models Maximum Fuel flow (CFH) 931 1898 210
Ori f i ce si ze 0.2188 0.3125 0.109
Mod Valve Bypass Orifice Blue Aluminum Yellow
Minimum operating pressure 1 1 1
Maximum operating pressure 15 15 15
Minimum line size 3/8" 3/8" 1/2"
Natural Gas Maximum Fuel flow (CFH) 2496 4643 500
Models Or ifice size 0. 3438 0.4688 0.156
Mod Valve Bypass Orifice Aluminum Aluminum Green
Minimum operating pressure 0.5 0.5 1
Maximum operating pressure 7 7 7
Minimum line size 1. 1/4" 1.1/4" 1"
Heater Dimensional Specifications
Heater Size
Inside Height
Inside Width
Inside length
6
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"
Series 2000 Downwind Heater
Air Pressure Switch and
Temperature Sensor Box
Installation
1. Using air switch box as a
guide, mark 2 holes on plenum side wall appproximately
24" to right of transition centered up and down in plenum.
2. Drill air switch filter hole 5/8"
diameter for snug fit. Drill temperature sensor hole 5/8" or
larger to accommodate mounting
nut.
3. Mount Box to Bin using (4)
self drilling screws
HEATER INSTALLATION
4. Caulk between housing and sidewall to seal.
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.
Air Switch Box Assembly
Transition Hi-limit Installation
Figure 1: The transition connecting the Series 2000 Heater to the bin with
the sensor in place.
7
HEATER INSTALLATION
Bin Configuration
Series 2000 Downwind Heater
IMPORTANT! When
mounting (2) heaters on a
bin it is imperative that
they be situated as
illustrated in this drawing. Plenum thermostat
must be to the right of
master heater and master
heater must be to the
right of slave heater .
THIS TABLE IS NOT INTENDED AS A DRYING GUIDE.
IT SHOULD BE USED AS A REFERENCE FOR SETTING MAXIMUM PLENUM
TEMPERATURE FOR SAFE OPERATION.
Operating Temperature Table
PMET-OL
HCTAB
0
02-5
NROC
ECIR
SNAEB
&
TAEHW
EVOBA
TNEIBMA
PMET
0
01-5
EVOBA
TNEIBMA
PMET
0
02-5
EVOBA
TNEIBMA
PMET
-HGIH
PMET
YRDHCTAB
GNIRRITSON
0
021
0
001
0
011
-HGIH
PMET
HTIW
GNIRRITS
0
041
SUOUNITNOC
WOLF
)GNITALUCRICER(
0
061
IMPORTANT!
DO NOT EXCEED
PLENUM
TEMPERATURES
0
001
0
021
TON
DEDNEMMOCER
TON
DEDNEMMOCER
LISTED IN TABLE
8
Series 2000 Downwind Heater
HEATER INSTALLATION
Heater Unit
1. Be sure fan unit is installed and
wired to meet local codes. Be
sure equipment is well grounded
(see page 10).
2. A separate neutral is required
for 120 volt heater circuit in 220
volt 1PH and 3PH fan units. For
460 volt fan units a separate 120
volt power supply or transformer
is required.
3. Run 5-wire black cord from
heater unit to fan unit and se-
cure to fan.
4. Orange and red wires should be
connected in series with coil in
fan. When contacts in heater be-
tween these wires open fan
Wiring
Figure 2: Wiring diagram for the fan and heater unit.
shuts down. Recommended wiring is shown in Figure 2.
5. Black and white wires should be connected to a fused 120V
power supply as shown. Green wire should be connected to
ground in fan. Heater should have power, even with fan off.
Figure 3: Secondary heater wiring diagram.
SECONDARY HEATER UNIT
1. Secondary heater unit runs as a slave of heater
unit #1 and requires no plenum temperature
sensor.
2. Run (2) 20 gauge (minimum) wires from sec-
ondary 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 in parallel with sec
ondary heater unit.
9
HEATER INSTALLATION
Machine To Earth
Ground
It is very important that a machine
to earth ground rod be installed at
the fan. This is true even if there is
a ground at the pole 15 feet away.
This ground needs to be as close to
the fan as possible, but no more than
8 feet away. The ground rod should
be connected to the fan control panel
with at least a #6 solid bare copper
ground wire, or in accordance with
local requirements. The machine to
earth ground provides additional
safety if there is a short. It also provides the grounding necessary for
long life and operation of the solid
state circuit boards used on control
circuits and the electronic ignition
systems.
(Ground rods and wires are not supplied by Airstream). It is recommended that
the rod not be driven into dry ground. The following steps ensure proper ground
rod installation:
1. Dig a hole large enough to hold 1 to 2 gallons of water.
2. Fill hole with water.
Series 2000 Downwind Heater
Figure 4: Use a
#6 or approved
size bare copper
ground wire.
Install a 5/8"
diameter 8' long
copper-clad
ground rod, 2'
away from the
foundation and 1'
below the surface
of the ground or
in accordance
with local
requirements.
Proper Installation Of The Ground Rod
Dig a hole large enough to hold 1
or 2 gallons of water. Work the
ground rod into the earth until it is
completely in the ground.
3. Insert rod through water and jab it into the ground.
4. Continue jabbing the rod up and down, the water will work its way
down the hole, making it possible to work the rod completely
into the ground. This method of installing the rod gives a good
conductive bond with the surrounding soil.
5. Connect the bare copper ground wire to the rod with the proper
ground rod clamp.
6. Connect the bare ground wire to the fan control boxes with a
grounding lug. See figure 4.
7. Ground wire must not have any breaks or splices. Insulated
wire is not recommended for grounding.
Previously Installed Units
It is recommended that previously installed units be checked to see
that a machine to earth ground has been installed by an electrician.
10
Series 2000 Downwind Heater
HEATER 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 elec-
trician should make all wiring
installations.
ALWAYS DISCONNECT
AND LOCK OUT
BEFORE WORKING ON
OR AROUND HEATER
Fuel Connection
Liquid Propane Models
1. L.P. models are designed to run on liquid pro
pane with liquid draw from the propane tank.
A void 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
7) to liquid pipetrain on heater. Have a qualified
gas service person inspect installation to be sure
that everything is installed according to local
codes and ordinances.
POWER
2. Run proper size line (see specifications on page
3. After installation is complete check all connec-
1. Natural gas models are designed to run directly
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.
external vaporizer.
7) to pipetrain on heater. Have a qualified gas
service person inspect installation to be sure that
everything is installed according to local codes
and ordinances.
tions for leaks. DO NOT USE FLAME FOR
LEAK TESTING.
Natural Gas Models
off of a supply tank or from a separate
external vaporizer.
3. After installation is complete check all connections for leaks with liquid detergent or comparable. 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 a supply tank or from a separate
2. Run proper size line (see specification on page 7)
to pipetrain 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 INSTALLATION
Figure A
Series 2000 Downwind Heater
Installing Optional Humidity Sensor
1. Humidity sensor should be mounted 6-8"
right of the airswitch/temperature sensor
box. See Figure A.
2. Using sensor as a guide drill or knock-out
7/8" diameter hole in the center of the
plenum on the bin sidewall. If you are
using sensor to sense drying air humidity.
3. Insert pipe nipple from sensor housing
throughhole in side wall and use selfdrilling screws to mount to sidewall.
Figure B
4. Do not caulk sensor box openings on side
of box, they are for air escape.
12
Figure B
Series 2000 Downwind Heater
OPERATING PROCEDURE
The control panel display showing initial start up.
Standard electrical safety practices and codes should
be used when working with a heater. Refer to the
National Electric Code Standard Handbook by
the National Fire Protection Association. A quali-
fied electrician should make all wiring installations.
ALWAYS DISCONNECT
AND LOCK OUT POWER
BEFORE WORKING ON
OR AROUND HEATER
Power Up
All safety and high limit switches are checked upon
power up. 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 condi-
tion. There is no way to bypass an error condition. It
must be fixed. (See errors on page 21)
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 operator for gets 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
"FAN 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 "FAN BYPASS" switch.
13
OPERATING PROCEDURE
Normal Operating Displays With Heater Not Running
Series 2000 Downwind Heater
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.
All safeties or high limits 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 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 17).
14
The heater display with fan on (airflow).
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