GSI PNEG-823 User Manual
Deluxe Downwind Centrifugal
Heater Installation and
Operating Instructions
Model # CH_-_ _-_ _-D (HIGH)
Model # CL_-_ _-_ _-D (LOW)
Owner ’s Manual
PNEG-823
Date: 07-18-08
PNEG-823
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-Low (High-Low only)
15. Modulating valve holds temperature within 1 degree (modulating units only)
16. All decals and serial number tag
17. Aesthetic appearance
18. Manual
Tester Signature:
Date:______________________________
______________________________
This equipment shall be installed in accordance with the current installation codes for gas burning
appliances and equipment, CAN1-B149.1 and B149.2, or applicable provincial regulations which
should be carefully followed in all cases. Authorities having jurisdiction should be consulted before
installations are made.
2 PNEG-823 Deluxe Downwind Heater
Table of Contents
Contents
Chapter 1 Safety ..................................................................................................................................................5
Safety Guidelines ............................................................................................................................... 5
Fuel Warning ...................................................................................................................................... 6
Power Warning ................................................................................................................................... 6
Proper Use of Product ........................................................................................................................ 6
Heater Operation ................................................................................................................................ 6
Safety Instructions .............................................................................................................................. 7
Chapter 2 Decals .................................................................................................................................................9
Chapter 3 Heater Installation ...........................................................................................................................10
Machine to Earth Ground ............................. .... ... ... ... .... ... ... ... .... ... ... ... ... .......................................... 10
Proper Installation of the Ground Rod .............................................................................................. 10
Previously Installed Units ................................................................................................................. 11
Fuel Connection ............................................................................................................................... 12
Chapter 4 Installation ........................................................................................................................................13
Heater Specifications .................................................................................................................... ... 13
Plenum Thermostat Mounting ................................ ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ................ 13
Transition High-Limit Installation ...................................................................................................... 14
Chapter 5 Bin Configuration ............................................................................................................................15
Operating Temperature Table ................... ... .... ... ... ... .... ... ... ... .......................................................... 15
Chapter 6 Second Heater Installation ............................................................................................................. 16
For Units Using HF-7318 Control Board .......................................................................................... 16
Installation for Standard Units .......................................................................................................... 16
Additional Steps for High-Low Units ....................................... .... ... ... ... ... .... ... ... ................................ 16
Electrical Installation (230V Fans) .................................................................................................... 17
Electrical Installation (460V Fans) .................................................................................................... 18
Chapter 7 Wiring Diagram ................................................................................................................................19
Chapter 8 Operating Procedure .......................................................................................................................20
Cycling Heater Operation ................................................................................................................. 20
High-Low Heater Operation ................. ... ... ... .... ... ... ... .... ................................................................ ... 20
Modulating Valve Operation ................ ... .......................................................... ... .... ... ... ... ... .... ... ...... 21
10 HP-15 HP Units BTUs per Gauge Pressure (PSI) Propane Models (Approximate) .................... 22
10 HP-15 HP Units BTUs per Gauge Pressure (PSI) Natural Gas Models (Approximate) .............. 22
20 HP-40 HP Units BTUs per Gauge Pressure (PSI) Propane Models (Approximate) .................... 23
20 HP-40 HP Units BTUs per Gauge Pressure (PSI) Natural Gas Models (Approximate) .............. 24
Low-Temperature Units BTUs per Gauge Pressure (PSI) Propane Models (Approximate) ............ 24
Low-Temperature Units BTUs per Gauge Pressure (PSI) Natural Gas Models (Approximate) ...... 24
Adjusting the Vaporizer .................................................................................................................... 25
PNEG-823 Deluxe Downwind Heater 3
Table of Contents
Chapter 9 Parts List ..........................................................................................................................................26
DW Propane Vapor High-Fire Pipetrain Components ...................................................................... 27
DW Propane Vapor High-Low Fire Pipetrain Components .............................................................. 28
DW Propane Vapor Modulating Pipetrain Components ................................................................... 29
DW NG High-Fire Pipetrain Components ......................................................................................... 30
DW NG High-Low Fire Pipetrain Components ................................................................................. 31
DW NG Modulating Pipetrain Components .............................. ........................................................ 32
DW LP High-Fire Pipetrain Components .......................................................................................... 33
DW LP High-Low Pipetrain Components ......................................................................................... 34
DW LP Modulating Pipetrain Components ....................................................................................... 35
40 HP DW High-Temperature Heater Parts ..................................................................................... 36
40 HP DW Low-Temperature Heater Parts ...................................................................................... 37
DW Gas Heater Control Box Parts ................................................................................................... 38
DW Propane Vapor Pipetrain Parts .................................................................................................. 39
DW Propane Vapor High-Low Pipetrain Parts .................................................................................. 40
Chapter 10 Warranty .........................................................................................................................................41
4 PNEG-823 Deluxe Downwin d H e at er
1. Safety
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.
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 indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
NOTE indicates information about the equipment that you
should pay special attention.
DANGER! BE ALERT!
Personnel operating or working around electrical equipment 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.
PNEG-823 Deluxe Downwind Heater 5
1. Safety
Fuel Warning
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.
Be sure fuel supply system complies with all local codes for LP gas installations.
DO NOT USE FLAME FOR LEAK TESTING.
Power Warning
Be sure power is disconnected and locked out before installation. Failure to do so may cause serious
injury or death.
IMPORTANT: Heater must be interlocked with fan for safe operation.
IMPORTANT: Thermostat must be installed for safe operation.
Proper Use of Product
This product is intended for the use of grain drying onl y. Any other use is a misuse of this product. 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. Guards are removed
for illustration only. All guards must be in place before and during operation.
Heater Operation
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 GSI Deluxe Downwind Centrifugal Heater. Many models are
available to accommodate low, medium or High-Temperature grain conditioning.
6 PNEG-823 Deluxe Downwind Heater
1. Safety
Safety Instructions
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 proced ures 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.
Follow Safety Instructions
Carefully read all safety messages in this manual and
safety signs on your machine. Keep signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from the manufacturer.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machinery in proper working condition.
Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
If you do not understand any part of this manual or need
assistance, contact your dealer.
Install and Operate Electrical Equipment Properly
Electrical controls should be installed by a qualified electrician
and must meet the standards set by the National Electrical Code
and all local and state codes.
Disconnect and lock out all power sources before installing
wires/cables or servicing equipment.
Read and Understand Manual
Electric Shock Hazard
PNEG-823 Deluxe Downwind Heater 7
1. Safety
Install and Operate Gas-Fired Equipment Properly
Fuel supply should be installed by a qualified gas
technician and must meet local and state codes for
gaseous fuel supplies.
Disconnect and lock out all fuel sources before
servicing equipment.
Prepare for Emergencies
Be prepared if fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital and fire department near your telephone.
Explosive Gases
Keep Emergency Equipment
Quickly Accessible
Wear Protective Clothing
Wear close fitting clothing and safety equipment appropriate
to the job.
Remove all jewelry.
Long hair should be tied up and back.
Safety glasses should be worn at all times to protect eyes
from debris.
Wear gloves to protect your hands from sharp edges on
plastic or steel parts.
Wear steel toe boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoe strings.
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Eye Protection
Gloves
Steel Toe Boots
Respirator
Hard Hat
Wear hard hat to help protect your head.
Wear appropriate fall protection equipment when working at
elevations greater than six feet (6').
8 PNEG-823 Deluxe Downwind Heater
Fall Protection
2. Decals
The GSI Group recommends contacting your local power company, and having a representative survey
the installation so the wiring is compatible with their system, and adequate p ower is supplied to the unit.
If a decal is damaged or missing, contact:
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 217-226-4421
A free replacement will be sent to you.
Roof Damage Warning and Disclaimer
CAUTION!
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
Stay clear of rotating
blade. Blade could start
automatically. Can cause
serious injury. Disconnect
power before servicing.
GSI 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. GSI
does not recommend the use of downward 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 to freeze.
WARNING
DC-1225
WARNING
Flame and pressure beyond
door can cause serious
injury. Do not operate with
service door removed. Keep
head and hands clear.
DC-1227
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
Keep clear of all augers.
DO NOT ENTER this bin!
If you must enter the bin:
1. Shut off and lock out all power.
2. Use a safety harness and safety line.
3. Station another person outside the bin.
4. Avoid the center of the bin.
5. Wear proper breathing equipment or respirator.
DC-1224
PNEG-823 Deluxe Downwind Heater 9
Failure to heed these
warnings will result in
serious injury or death.
DC-GBC-1A
3. 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' away. This ground needs to be as close to the fan as possible, but no more than
8' 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.
Figure 3A
Dig a hole large enough to hold one (1) or two (2) gallons of water. Work the ground rod into the
earth until it is completely in the ground.
Proper Installation of the Ground Rod
(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 one (1) to two (2) gallons of water.
2. Fill hole with water.
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.
10 PNEG-823 Deluxe Downwind Heater
3. Heater Installation
Proper Installation of the Ground Rod (Continued)
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 3B.)
7. Ground wire must not have any breaks or splices. Insulated wire is not recommended for grounding.
Figure 3B
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.
Previously Installed Units
It is recommended that previously installed units be checked to see that a machine to earth ground
on Page 10 has been installed by an electrician.
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.
Always disconnect and lock out power before working on or around heater.
IMPORTANT: Do not use propane tan ks that have previously been used for ammonia unless they have
been purged according to procedures of the National LP Association.
Fuel supply system must comply with local codes for LP gas installation.
PNEG-823 Deluxe Downwin d Heater 11
3. Heater Installation
Fuel Connection
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 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
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 with liquid detergent or comparable.
Wear rubber gloves and eye protection. Avoid contact with liquid propane. DO NOT USE FLAME
FOR LEAK TESTING.
(see Specification on Page 13)
to liquid pipetrain on heater. Have a qualified gas
Propane Vapor Models
1. Propane vapor models are designed to run directly off of a supply tank or from a separate
external vaporizer.
2. Run proper size line (see Specification on Page 13) 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.
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 vaporizer.
2. Run proper size line (see Specification on Page 13) 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.
12 PNEG-823 Deluxe Downwind Heater
Heater Specifications
4. Installation
Centrifugal Heater Specifications
All Models
Liquid Models
Vapor Models
Natural Gas Models
High-Temperature
Model
BTU Rating 4000000 500000
Weight 145 135
Maximum Fuel Flow (GPH) 43 N/A
Orifice Size 0.25 N/A
Minimum Operating Pressure 3 N/A
Maximum Operating Pressure 30 N/A
Minimum Line Size 3/8" N/A
Maximum Fuel Flow (CFH) 1590 210
Orifice Size 0.25 0.109
Minimum Operating Pressure 2 1
Maximum Operating Pressure 30 15
Minimum Line Size 1" 1/2"
Maximum Fuel Flow (CFH) 4200 500
Orifice Size 0.375 0.156
Minimum Operating Pressure 1 1
Maximum Operating Pressure 15 7
Minimum Line Size 1-1/4" 1"
Low-Temperature
Model
Heater Dimensional Specifications
Heater Size 10-15 20-30 40
Inside Height 30-1/4" 33-1/4" 33-1/4"
Inside Width 19-1/2" 21-3/4" 23-11/16"
Inside Length 24" 24" 24"
Plenum Thermostat Mounting
The plenum thermostat is the 4 x 4 white box with knob that is preconnected to heater when heater is
ordered with thermostat.
1. 24" to the right side of the transition, drill one (1) 3/8" hole (High-Temperature) or 1-1/2" hole
(Low-Temperature) in the center of the plenum in a valley (4.00" corrugation) or hill
(2.66" corrugation) on 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.
4. Use four (4) self-drilling screws to mount the housing to the bin sidewall.
5. Caulk between the housing and the sidewall to seal.
PNEG-823 Deluxe Downwind Heater 13
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