GSI PNEG-824 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-824
1
Series 2000 Downwind Heater
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
Series 2000 Downwind Heater
_____ 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".
"FLAME" should appear on lower right hand corner of screen.
_____ 15. Adjust pressure to 10 psi (lp units) 5 psi (ng units).
_____ 16. Check pipe train for leaks with soapy water.
_____ 17. Temperature should rise to 120 degrees. Screen should read "LO-FLAME" and unit
should cycle to lo-flame. (hi-lo units only)
_____ 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,
followed by temperature. Screen should read "NO AIRFLOW".
_____ 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 appear on lower right hand corner of screen.
_____ 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
"ERROR 000" and "FLAME OUT".
_____ 30. Check heater visually to see that all decals are in place and correctly located.
_____ 31. Place owners manual in control box.
CHECKLIST
Tester Signature___________________________________________
Date____________________________________
3
Series 2000 Downwind Heater
4
Series 2000 Downwind Heater
Safety 6
Series 2000 Heater Installation
High Temperature Heater Specifications 8
Low Temperature Heater Specifications 8
Temperature Sensor Box 9
Transition Hi-Limit Installation 9
Bin Configuration/Operating Temperature Table 10
Heater Unit Wiring 11
Secondary Heater Unit Wiring 11
Machine To Earth Ground 12
Proper Installation Of The Ground Rod 12
Previously Installed Units 12
Fuel Connection For Liquid Propane Models 13
Fuel Connection For Propane Vapor Models 13
Fuel Connection For Natural Gas Models 13
Installing Optional Humidity Sensor 14
Series 2000 Operating Procedure
Power Up 15
Normal Operating Displays With Heater Not Running 16
Starting The Dryer 17
Setting Gas Pressure 17
BTU's Per Gauge Pressure (PSI) 10-15 hp Models (Approximate) 19
BTU's Per Gauge Pressure (PSI) 20-40 hp Models (Approximate) 20
BTU's Per Gauge Pressure (PSI) Lo-temp Models (Approximate) 22
Adjusting The Vaporizer 23
Running The Dryer 23
Programming Set Points 24
Programming Hours To Shutdown 25
Drying Grain In The Hours To Shutdown Mode 25
Run Hours Display 25
Multiple Heater Notes 25
Modulating Valve Operation 26
Factory Configuration
Configuration Dip Switches 27
Error Conditions
Limit Switches 28
Multiple Heater Error Conditions 28
Misc Error Numbers 28
Series 2000 Heater Service 29
Series 2000 Wiring Diagram 30
Warranty 32
TABLE OF CONTENTS
5
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, may result in minor or moderate
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. Avoid 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, may 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.
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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 PRES-
SURE FROM FANS OR OTHER AIR MOVING SYSTEMS.
ADEQUATE VENTILATION AND/OR "MAKEUP AIR" DE-
VICES SHOULD BE PROVIDED FOR ALL POWERED AIR
HANDLING SYSTEMS. GSI DOES NOT RECOMMEND
THE USE OF DOWNWARD FLOW SYSTEMS (SUCTION).
SEVERE ROOF DAMAGE CAN RESULT FROM ANY
BLOCKAGE OF AIR PASSAGES. RUNNING FANS DUR-
ING HIGH HUMIDITY/COLD WEATHER CONDITIONS
CAN CAUSE AIR EXHAUST OR INTAKE PORTS
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SPECIFICATIONS
Series 2000 Downwind Heater
Centrifugal Heater Specifications
Hi-Temp Hi-Temp Lo-Temp Model
10-15HP 20-40HP All units
All Models BTU Rating 2225000 4500000 500000
Weight 145 145 135
Liquid Mo dels Maximum Fuel flow (GPH) 24 49 N/A
Orifice size 0.2188 0.3125 N/A
Mod Valve Bypass Orifice Blue Aluminum Yellow
Minimum operating pre ssure 1 1 N/A
Maximum operating pressure 15 15 N/A
Minimum line size 3/8" 3/8" N/A
Vapor Models Maximum Fuel flow (CFH) 931 1898 210
Orifice size 0.2188 0.3125 0.109
Mod Valve Bypass Orifice Blue Aluminum Yellow
Minimum operating pre ssure 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 Orifice size 0.3438 0.4688 0.156
Mod Valve Bypass Orific e Aluminum Aluminum Gre en
Minimum operating pre ssure 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
8
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
PLENUM TEMPERATURE
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 transi
tion, drill one 3/8" hole in the cen
ter 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.
HEATER INSTALLATION
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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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
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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.
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