AXIAL FAN HEATER. Owner's & Operator's Manual ATTENTION

Transcription

1 AXIAL FAN HEATER Owner's & Operator's Manual ATTENTION Pay close attention when you see this triangular symbol. It will be visible throughout this manual and on decals. Obey the Dangers, Warnings and Cautions. YOUR SAFETY IS INVOLVED! READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING HEATER! DANGER DO NOT OPERATE THIS UNIT WITHOUT GUARD(S) IN PLACE. STOP FAN AND LOCKOUT POWER TO ADJUST, SERVICE OR CLEAN. KEEP CHILDREN AND PERSONS NOT FAMILIAR WITH EQUIPMENT AWAY. WITHOUT PROPER THERMOSTAT OR OTHER CONTROL, THIS UNIT CAN CREATE DANGEROUS HEAT IN AN ENCLOSED AREA. FAILURE TO HEED WILL RESULT IN SERIOUS INJURY OR DEATH! December Manufactured by A Division of GLOBAL Industries, Inc, 9364 North 45th Street Omaha, Nebraska 68112

2 GENERAL STATEMENT WARNING Watch for this warning symbol! It will always be accompanied by important information regarding Safety, Warnings, and Precautions. ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! TO THE OWNER Occupational safety is of prime concern to NECO. This Owner s and Operator s Manual is provided to help ensure the safety of the operator as well as others who may come in contact with the equipment. It is your responsibility as an owner, operator, or supervisor to know what specific requirements, precautions, and work hazards exist and to make these known to all persons working with the equipment or who are in the area, so that they may take any needed safety precautions. Failure to read this Owner s & Operators Manual or to understand and heed its safety instructions constitutes a misuse of the equipment. We at NECO are continually testing and improving our products to provide the most efficient and economical grain handling equipment available. We cannot be responsible, however, for upgrading or changing units previously sold when making improvement to subsequent models. The NECO equipment that you have just purchased will provide years of dependable service when properly maintained. Your work load will be lightened and you ll save valuable time. Welcome to the growing number of satisfied NECO equipment owners. For a period of one (1) year after shipment of goods by Buyer to the Buyer s customer, NECO will supply free of charge, F.O.B. NECO s factory, Omaha, Nebraska, replacement parts for any parts that prove to be defective due to workmanship or material.* Defective parts must be returned, freight-prepaid, to the NECO Factory in Omaha, Nebraska. You must obtain a Return Authority form from NECO prior to returning goods. GOODS NOT MANUFACTURED BY NECO CARRY ONLY THE MANUFACTURER S WARRANTY. LIMITED WARRANTY* THIS UNDERTAKING IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUD- ING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. 2 FAILURE TO FOLLOW THE INSTRUCTIONS CON- TAINED IN THIS MANUAL AS WELL AS ANY OF THE CONDITIONS LISTED BELOW WILL CAUSE THIS LIMITED WARRANTY TO BE VOIDED. 1. Improper assembly 2. Improper installation (including power and wiring) 3. Unauthorized alteration of goods 4. Operating the unit when repairs are needed 5. Use of unauthorized parts 6. Operation by children or uninstructed personnel 7. Processing of materials that are abrasive, that do not flow freely, or that are otheriwise unsuited for processing in a grain dryer 8. Abuse or misuse of the unit or of any of its components 9. Accidents *This limited warranty does not extend to parts designed to wear in normal operation and be replaced periodically or to damage caused by negligence, accident, abuse, or improper installation or operation. LIMITATION OF LIABILITY BUYER AGREES THAT IN NO EVENT SHALL NECO HAVE LIABILITY FOR DIRECT DAMAGES IN EXCESS OF THE CONTRACT PRICE OF THE GOODS FOR WHICH THE CLAIM IS MADE. Buyer further agrees that in no event shall NECO have liability for loss of use, loss of profits, or for any indirect, incidental, or consequential damages on any claim of any kind.

3 Table of Contents GENERAL STATEMENT... 2 CHECK LIST FOR HEATERS... 4 SAFETY... 5 OPERATOR QUALIFICATIONS... 5 OPERATING PROCEDURES... 5 POWER LOCK OUT... 6 MACHINE INSPECTION... 6 WORK AREA SAFETY... 6 AVOID STRUCTURAL DAMAGE... 7 AVOID FIRE, EXPLOSION, AND ASPHYXIATION HAZARDS... 7 INSTALLATION DATA AND MOUNTING PAD... 8 INSTALLATION... 9 GROUNDING FUEL SUPPLY PROPANE NATURAL GAS COMPONENT IDENTIFICATION AND FUNCTION SETTING THE DRYING TEMPERATURE PRE-START CHECK INITIAL START-UP USING PROPANE HEATER OPERATIONS RECOMMENDED DRYING TEMPERATURES WIRING DIAGRAM NOTICE DRYING PRECAUTIONS JOHNSON CONTROLS SERIES V50 FOR SELF-OPERATED MODULATING VALVES TROUBLESHOOTING GUIDE MAINTENANCE Replacement Parts

4 CHECK LIST FOR HEATERS 1. ALL WIRE CONNECTIONS SECURED 2. SPARK PLUG SECURED - SET 3/16" 3. ALL NUTS AND BOLTS ARE TIGHT 4. CHECK FOR GAS LEAKS 5. FLAME PROBE TIGHTNESS 6. ON/OFF SWITCH 7. PRESSURE GAUGE READING PROPERLY 8. REGULATOR ADJUSTED PROPERLY 9. CHECK FOR PROPER GAS VALVE FUNCTION 10. TEST WITH THERMOSTAT 11. CHECK BURNER FOR PROPER BURN 12. CHECK FOR CORRECT HEAT RISE 13. CHECK AESTHETIC APPEARANCE 14. DECALS/ SERIAL NUMBER TAG 15. IS MANUAL IN CONTROL BOX 16. TEST FIRED AT SEVERAL PRESSURE SETTINGS TESTERS SIGNATURE DATE: SERIAL NUMBER 4

5 SAFETY OPERATOR QUALIFICATIONS Operation of this farm equipment shall be limited to competent and experienced persons. In addition, anyone who will operate or work around power equipment must use good common sense. In order to be qualified, operator must also know and meet all other requirements, such as: 1. Some regulations specify that no one under the age of 16 may operate power machinery. This includes farm equipment, It is your responsiblity to know what these regulations are in your own area or situation. 2. Current OSHA regulations state in part: "At the time of intial assignment and at least annually thereafter, the employer shall instruct every employee in the safe operation and servicing of all equipment with which the employee is, or will be involved."* 3. Unqualified persons are to stay out of the work area. The "Work Area" is defined as the area surrounding the grain handling equipment. 4. A person who has not read and understood all operation and safety instructions is NOT qualified to operate the machine. * Federal Occupational Safety & Health Standards for Agriculture Subpart D, Section (a) (6). OPERATING PROCEDURES During the operation of your farm equipment, one person shall be designated to monitor the machinery. It is also good practice for all qualified persons involved to visually inspect the equipment periodically during any actual operation. You should be alert for any unusual vibrations, noises, and loosening of any fasteners. CAUTION: 1. Observe work area restrictions. 2. Keep all safety shields and devices in place. 3. Make certain everyone is safely clear before operating or moving farm equipment. 4. Keep hands, feet, and loose clothing away from moving parts. 5. Always disconnect power before servicing equipment! NOTE: Foreign customers are responsible for knowing and applying their local safety regulations. 5

6 POWER LOCK OUT It is essential to inspect your fan and heater before turning on the power. Know how to shut down the fan anf heater power in an emergency! Prior to any servicing or adjusting of your equipment, make certain to shut down the power and lock it out. 1. Electric motors and controls shall be installed by a qualified electrician. Installation must meet standards set by the National Electrical Code and all local and state codes. 2. Always disconnect and lock out power before servicing the fan and heater. 3. Reset and motor starting controls must be located so that the operator has a full view of the entire operation. Always keep children away from unit! 4. Make certain that all fan guards are reinstalled after servicing. A main power disconnect switch capable of being locked only in the OFF position shall be installed. This shall be locked out whenever the equipment is being serviced. MACHINE INSPECTION After delivery of your new fan/heater and/or completion of assembly and before each use, inspection of the equipment is mandatory. This inspection should include but not be limited to: 1. Check to see that all guards listed in the assembly instructions are secured in place and are functional. 2. Check that all fasteners are tight. 3. Before starting fan, be sure that fan interior and inlet is clear of any debris. 4. Make certain that impeller rotates freely. 5. Open roof hatches before use. 6. Inspect all electrical and gas connections. Check for leaks with soapy water. 7. Are all safety decals clean and readable? 8. Before starting heater read start-up procedures. WORK AREA SAFETY People not involved in the operation should not be allowed into the work area. It shall be the duty of all operators to see that children and/or any other unqualified persons stay out of the work area. Trespassing into the work area by anyone not involved in the actual operation, or trespassing into a hazardous area by anyone, shall result in an immediate shut down by the operator. It is highly recommended to wear hearing protection when standing near operating fan. Prior to start up and during operation, it shall be the responsibility of all operators to see that the work area is clear. It must be clean and free of any debris and misplaced tools which could cause accidental tripping and/or falling. 6

7 AVOID STRUCTURAL DAMAGE Avoid Structural Damage to your Bin Ensure that all roof vents are open and unobstructed. Ensure adequate ventilation. NECO recommends a minimum of 1 square foot (929 cm 2 ) of vent area per every 1000 cfm (21 m 3 /min) fan air input. Make certain that all fans are installed for positive pressure aeration (push system). Roof exhausters should be interlocked with aeration fans so that roof exhausters can run only when the aeration fans are running. Never operate your bin aeration system when icing of the roof vent is possible. Roof vent icing can occur when the ambient air temperature is below 35 F (2 C) and the relative humidity of the air is 90% or greater. Check with your local weather bureau. AVOID FIRE, EXPLOSION, AND ASPHYXIATION HAZARDS NECO Heaters are designed for drying crop output in grain bins. They provide heated air via grain bin plenums (found underneath full-floor bins) or via in-floor ductwork. Consult the NECO factory before attempting to use heaters for EZEE-DRY applications. Never use NECO heaters to heat buildings, sheds, barns, etc. because of hazards posed by the flame and by the output of carbon monoxide. Never install or use NECO heaters where a high concentration of grain dust or flammable liquids or vapors exists because explosions could result. A common grain bin filled with grain such as shelled corn, beans, or wheat is not considered an explosive (volitile) environment. A metal or concrete silo filled with finely milled grain dust, however, does consitute an explosive environment. Never allow anyone to enter the grain bin when a fan and heater is operating! Gasses given off by the burner (including carbon monoxide and carbon dioxide) could cause death. When installing the heater make sure that the plenum area is clean of any flammable debris especially within 10 ft. of the heater transition entrance. At the end of each season clean the transition, heater entrance, and plenum. Good housekeeping is essential to prevent bin fires. Before loading the bin with grain, make certain that the plenum floor or ductwork is not damaged or plugged. Also, check the operation of the aeration fan to make certain that the roof vents are unobstructed. FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH! BE EXTREMELY CAREFUL OF THE HIGH VOLTAGE PRODUCED BY THE IGNITION UNIT. NOTE: IF YOU EXPERIENCE PROBLEMS WITH YOUR HEATER, CONTACT YOUR DEALER FIRST. IF THEY ARE UNABLE TO HELP, CALL THE SERVICE MANAGER AT NECO. THE PHONE NUMBER IS OR (402)

8 INSTALLATION DATA and MOUNTING PAD Unless otherwise noted [ ] indicates length measurement in millimeters. Bin Heater When installing your heater unit, plan the system such that proper consideration is given to: 1. For even heat distribution. Install the heater inline with the unloading auger (see Figure 1). For more than one heating unit, install the second heater a minimum of 1-1/2 bin sheets apart. The thermostat or other controlling device should be installed between the two heaters. All heaters are equipped with a terminal strip where the customer supplied thermostat, humidistat, or combination unit for controlling the heater output must be wired. A control is not required on units equipped with a modulating valve. To install a modulating valve cut a 1¼" hole 3 ' from the side of the transition below the drying floor. Attach the bracket on the probe over the hole with screws shown in Figure 2. When not using a control device with a modulating valve heater, the two terminals on the terminal strip in the heater control box normally used for the control device must be jumped together to operate. For safety purposes though, a burner control device is ALWAYS recommended. 2. Minimize airflow resistance by running flooring at right angles to the unload auger. Floor supports should be parallel to the unload auger. IMPORTANT 3.During initial operation, with grain in bin, drill 6 to 8 evenly spaced holes in lower bin sheet under drying floor around the bin. Check for even temperature making necessary adjustments as required. This will allow for uniform drying and may prevent a potential fire hazard. NECO highly recommends that you install at least two or three thermometers equally spaced along the circumference of the grain bin plenum. Monitor the drying heat to avoid excessive temperatures. Unloading System SINGLE HEATING UNIT Bin Unload System TWO HEATING UNITS DUEL HEATING UNIT Figure. 1 Heater Positioning Fan BURNER CONTROL (THERMOSTAT/ HUMIDISTAT) Fan Heater Duel Burner 1 1/2 Control SHEETS MIN. (Thermostat/ FOR SECOND HEATER Humidistat) Spacing from 4' to within 45 of each other. Modulating Probe Keep under bin floor. Figure. 2 Modulating Valve Installation NOTE: When using two or more fans on the same bin, be sure to provide devices that will prevent reverse rotation of fans that are not running. This is to prevent damage to the fan motors. Examples of devices are: a) Simultaneous starting, b) Sequential starting (at 30 second intervals), c) Cover plates, and d) Shutters. 8

9 4. Fan and add-on heater mounting plane is the same as your grain bin.* *On MFS corrugated grain bins with a rolled in base angle, the fan and heater mounting needs to be 1½" lower. Place the fan and heater on a mounting pad or hang them off the side of the grain bin with cables. Hanging installations can prevent the costs and maintenance issues associated with poured concrete pads. NECO premium axial fans and axial heaters 24" and greater are equipped with cable attachment brackets (located at the handles). Use at a minimum a 3 /16" galvanized steel (or stainless steel) wire rope with appropriate fittings. Make certain the units are secured to prevent any wind-induced sideways motion. Centrifugal fans and heaters can also be hung by cables, but due to their weight and size the installations usually require angle brackets and heavier wire rope. Speak to your dealer or local millwright before attempting cable installations. It's very important that the unit is securely mounted. If you choose a poured concrete slab to mount your fan and heater on, it is recommended that the slab be approximately 6 inches thick [152] and 12" [305] wider on each side of the fan/heater. TIP: In order to reduce the chances of frost heave, the pad can be poured on top of several metal or concrete pilings which extend lower than average frost depth. 5. Make sure the bin transition discharge is of an equal area to your fan outlet. (See Figure 3.) INSTALLATION 1. Using the appropriate caulk (caulking rated at 200 F) caulk the Fan/Heater flanges. Connect the fan to the heater using nuts, bolts etc. Hand tighten these fasteners only. Note: use the appropriate adapter plates to connect Fans/Heaters and transitions. Do not weld onto transitions! Welding will cause distortions which could lead to vibrations during operation. 2. Place fan and heater on mounting pad. Make sure the units sit level. Any bending of the units will twist the housing and cause future problems. Note: Frost heave can cause Fan/Transition distortion and even vibration. 3. Wrench tighten the fan mounting bolts/nuts, followed by wrench tightening of the heater mounting nuts/bolts. Make sure heater/fan mountings are secure. A loose fan mounting will cause the fan to vibrate. Vibration can cause excessive wear on the fan motor bearings. 4. Wrench tighten all flange fasteners. AREA = 616 SQ. IN. [3974 sq. cm.] AREA= 56 X 11 = 616 SQ IN. [3974 sq. cm.] TRANSITION DISCHARGE OPENING FAN DISCHARGE Figure 3. 9

10 GROUNDING Connect your fan/heater to a ground rod that's no more than 8' [2.4 m] away. Connect the ground rod to the fan control panel with a minimum 6 AWG solid bare copper wire that's copper-clad and measures 5/8 diameter x 8 ft. long. Install the rod two feet from the fan/heater and/or bin foundation, and in accordance with local requirements. The ground rod-to-fan connection provides additional safety in the event of a short or lightning strike. It also provides the necessary grounding for operation and long life of control circuits in the fan and heater. Contact an electrical parts supplier to purchase ground rods and wires. ENCO recommends the rod not be driven in to dry ground. Follow the steps below to ensure proper rod installation. 1. Dig a ditch and fill it with 1-2 gallons [ Liters] of water. 3. Push a rod through the water and into the ground. 4. Jab the rod up & down allowing the water to work its way down the hole thus promoting a conductive bond with the surrounding soil. Drive the rod completely down. 5. Connect one end of the ground wire to the rod with an appropriate ground clamp. 6. Connect the other end to a ground lug connector inside the fan control box. Ground wires should have no splices or breaks. Don't use insulated wire for grounding. NECO recommends that previously installed units be checked for proper grounding. FUEL SUPPLY Gas suppliers will provide a tank, first stage regulator, and the connection to the dryer. He should test the connections for leaks. Storage tanks must be located at least 25 feet from all structures, depending on local codes. Check with your gas supplier for code specifications. Route the supply line in so line breakage from moving machinery is least likely. Line sizing charts have been included in this manual to assist in selecting the proper size pipe for the supply line. See charts on the next page. Propane The inside of the supply tank must be free of all contaminants. Raise one end of the liquid propane supply tank as shown in Figure 4. DO NOT USE supply tanks for propane if they've previously been used for anhydrous ammonia. Anhydrous ammonia residue will rapidly corrode the brass components. Fuel contaminants can also cause sooting and lead to ignition problems. NOTE: WARRANTY IS VOID IF FUEL SUPPLY CONTAINS ANYHYDROUS AMMONIA OR OTHER CONTAMINENTS. Vapor Valve Liquid Valve Tee Tank Liquid To Vaporizer Oil and Contaminants Figure 4. 10

11 IF OIL ENTERS THE HEATER FUEL SYSTEM, THE WARRANTY FOR FUEL TRAIN COMPONENTS WILL BE VOID. The supply tank should have a 1,000 gallon [3785 Liter] capacity and be equipped with a regulator capable of satisfying the BTU requirement of the heater at 35 PSI [241 kpa]. For systems using liquid propane, the tank should be equipped with a first stage liquid regulator of 25 gallons [95 Liters] per hour at 50 to 60 PSI [ kpa] under flow. Consult your natural gas representative for pressure available and assistance with the installation. The tank should be equipped with a vapor and liquid tap. NECO recommends initial heater start-up each day be done using the vapor tap. The liquid tap should have a rapid flow shutoff valve. If a line breaks the rapid flow shut-off valve will stop the flow of propane. The rapid flow valve should have a capacity of about 4 GPM [15 LPM]. To open this valve, open it part way to allow the pressure to equalize between the line and tank. Then fully open the excess flow valve. Consult your propane supplier for further information. Table 1 shows the vaporization rate of a 1,000 gallon [3785 Liter] tank at various temperatures when the tank is 25% full. If more heaters are used simultaneously or if low ambient tem- peratures are encountered, then a larger tank should be installed or additional tanks added in parallel. The vaporization rate of propane is constantly changing due to variables of temperature and amount of liquid in the tank. LINE SIZING CHART FOR VAPOR PROPANE FUEL Table 2 shows line lengths for systems running on gas vapor between the liquid propane tank and the heater allowing pressure drop of 1 PSI [6.9 kpa]. LINE SIZING CHART FOR LIQUID PROPANE FUEL Table 3 shows line lengths for systems running on liquid propane between the liquid propane tank and heater allowing pressure drop of 1 PSI [6.9 kpa]. CAUTION: SECURELY BLOCK TANK WHEELS WHEN HEATER CONNECTS TO A PORTABLE PROPANE TANK Cold reduces propane vapor pressure considerably. When it's very cold a propane-fueled heater may not get enough fuel to reach the desired operating temperature. Increase vapor pressure by warming the tank with an approved electric warming blanket. PROPANE VAPORIZATION RATE - 1,000 [3785 Liters] GALLON TANK Outside Temperature Vapor Pressure Volume Fluid Volume BTUs/Hour Celsius Fahrenheit PSI kpa Feet 3 /Hour Meter 3 /Hour Gallons/Hour Liters/Hour (000s) , , , , , , Table 1. Propane Vaporization Rate (Approximations) 11

12 LP Vapor Flow Rate LINE SIZING CHART FOR LP - GAS VAPOR Line Length - in feet [meters] Copper Tubing Schedule 40 Pipe BTU per hour (1,000s) Feet 3 [meter 3 ] per minute 3/8" 1/2" 5/8" 3/8" 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" [1.1] 192' [58.5] [1.7] 89' [27.1] [2.3] 53' [16.2] 286' [87.2] [3.4] 26' [7.9] 136' [41.5] 255' [77.7] [4.5] 15' [4.6] 80' [24.4] 270' [82.3] 147' [44.8] [5.7] 9' [2.7] 55' [16.8] 180' [54.9] 98' [44.8] 300' [91.4] 1, [11.8] 16' [4.9] 53' [16.2] 29' [8.8] 81' [24.7] 330' [100.6] 1, [17.0] 26' [7.9] 14' [4.3] 42' 12.8] 160' [48.8] 2, [22.7] 15' [4.6] 9' [2.7] 26' [7.9] 97' [29.6] 305' [93.0] 2, [28.3] 10' [3.0] 17' [5.2] 65' [19.8] 200' [61.0] 3, [34.0] 12' [3.7] 47' [14.3] 150' [45.7] 336' [102.4] 4, [45.3] 28' [8.5] 87' [26.5] 319' [97.2] 5, [56.6] 18' [5.5] 64' [19.5] 213' [64.9] 449' [136.8] 6, [68.0] 13' [4.0] 43' [13.1] 155' [47.2] 328' [99.9] 1054' [321.3] 7, [79.3] 10' [3.0] 33' [13.1] 115' [35.0] 245' [74.7] 809' ]246.6] 8, [90.6] 26' [7.9] 93' [28.3] 190' [57.9] 628' [191.4] Table 2. Line Sizing Chart for Vapor Propane Fuel. LP Vapor Flow Rate LINE SIZING CHART FOR LP - GAS LIQUID Line Length - in feet [meters] Copper Tubing - Type K Schedule 80 Pipe BTU per hour (1,000s) Gallons / Hour [liters / Hour] 3/8" 1/2" 5/8" 1/4" 3/8" 1/2" 3/4" 1" 1-1/4" [37.9] 328' [99.9] 1316' [401.1] 729' [222.2] 1, [75.7] 82' [25.0] 329' [100.3] 1410' [430] 182' [55.5] 825' [251.5] 3, [151.4] 20' [6.1] 82' [25.0] 354' [107.9] 46' [14.0] 205' [62.5] 745' [227.1] 5, [227.1] 9' [2.7] 36' [10.9] 157' [47.9] 20' [6.1] 92' [28.0] 331' [100.9] 7, [302.8] 20' [6.1] 83' [25.3] 11' [3.4] 51' [15.5] 187' [57.0] 735' [224.0] 9, [378.5] 13' [4.0] 56' [17.1] 7' [2.1] 33' [10.1] 119' [36.3] 470' [143.3] 12, [529.9] 29' [8.8.] 15' [4.6] 61' [18.6] 240' [73.2] 813' [247.8] 16, [681.3] 17' [5.2] 37' [11.3] 145' [44.2] 491' [149.7] 18, [757] 14' [4.3] 30' [9.1] 118' [36.0] 399' [121.6] 25, [1060] 15' [4.6] 60' [18.3] 204' [62.2] 27, [1136] 13' [4.0] 52' [15.8] 177' [53.9] 785' [239.3] Table 3. Line Sizing Chart for Liquid Propane Fuel. 12

13 USE EXTREME CARE WHEN WARMING A TANK NEVER USE A FLAME DIRECTLY ON THE TANK Natural Gas When using natural gas, your gas company will install a regulator that should be capable of producing 5 to 15 PSI [34 to 103 kpa] under flow. [NOTE: NECO does not supply regulators.] The regulator should be located at or near the dryer to reduce the size of the supply line. Consult your natural gas representative for pressure available and assistance in the installation The supply tank should be 1,000 gallon [3785 Liter] capacity and equipped with a regulator capable of satisfying the BTU requirement of the dryer at 35 PSI [241 kpa]. For systems using liquid propane, the tank should be equipped with a first stage liquid regulator of 25 gallons [95 Liters] per hour at 50 to 60 PSI [ kpa] under flow. (Consult your natural gas representative for pressure available and assistance with the installation.) The tank should be equipped with a vapor and liquid tap. It is recommended that initial heater start-up each day should be done using the vapor tap. The liquid tap should have a rapid flow shut-off valve. In the event of a line break, the rapid flow shut-off valve wll stop the flow of propane. The rapid flow valve should have a capacity of approximatly 4 GPM [15 Liters per minute]. To open this valve, open part way only, allow the pressure to equalize between the line and tank. After the pressure has equalized, the excess flow valve should be turned to the full open position. Consult with your propane supplier for further information. vapor & liquid tap. A short line should come out of each tap and meet at a T which then has a line going to the heater. 3) Before starting the heater, start the fan, close the liquid tap, and open the vapor tap. 4) Start heater up and let it run for at least 5 minutes. 5) Slowly open the liquid tap while slowly closing the vapor tap. Proceed until the liquid tap is completely open and the vapor tap is completely closed. Don't flood the heater. Adjust the vaporizer until the output plumbing from the vaporizer is warm to the touch. 6) If a vapor tap is unavailable, the unit can be started (with more difficulty) on the liquid tap. 7) Start fan. Very slowly crack open the liquid tap allowing just enough propane to vaporize naturally and build up a few pounds of pressure. Start heater. This will be a bit of trial and error due to ambient temperature conditions. Be very careful to allow only a small amount of liquid to vaporize. Do not throw open the valve, since this will cause a flooding effect in the fuel loop. 8) If the heater is flooded by liquid propane, shut off the tank supply. Open access panel to allow vapors to dissipate. The fuel loop may have to be taken apart at the union to allow the LP to evaporate. The heater will not start when flooded by liquid propane! Be extremely careful of vapors. Never smoke or have any type of ignition source nearby. SPECIAL NOTE: A heater equipped with a vaporizer coil must use liquid propane. Vapor propane is only used for initial warm-up. Using vapor propane constantly will overheat the vaporizer causing shut down. AVOID START-UP PROBLEMS BY DOING THE FOLLOWING 1) NECO LP model heaters require propane vapor for start-up. 2) The supply tank should be fitted with both a 13

14 COMPONENT IDENTIFICATION AND FUNCTION Fenwall ignition module (PN ) The ignition module controls the sequence of events leading to ignition. It also monitors the flame during operation. After power is applied to the burner via the toggle switch, the Fenwal module purges for 15 seconds. Next, the ignition module sends power to the vapor solenoid (liquid solenoid on LP models) causing the spark generator to spark for four seconds. If the flame probe senses flame, the solenoid valve(s) will remain open. If no flame is detected the solenoid valve(s) will close and stop the flow of gas. The burner will attempt to light three times before locking out. If lockout occurs see the troubleshooting section. To reset the ignition module and restart the ignition sequence, turn the toggle switch OFF and back ON. Vapor solenoid valve - 3/4" (PN ) On LP models (except Hi-Lo option models) this valve controls gas flow between the regulator and burner. It opens during the ignition. On natural gas models this valve controls gas flow between the customer supplied regulator and burner. It opens during the ignition. On Hi-Lo models (both LP and natural gas) this valve is opened to provide additional fuel to the burner when the burner control calls for additional heat (high fire position). Liquid solenoid - 3/8" (PN ) All LP models have this valve which controls the flow of liquid propane before it gets to the vaporizer. It opens during ignition and remains open during operation. Pressure gage (PN ) (PN Liquid filled) All models with a range of 0-15 PSI [0-100 kpa] have a pressure gage. Burner High Limit (PN F048410) The burner high limit is wired in series with the circuit. It serves as a safety interlock and shuts 14 down the burner if the burner housing gets too hot. It's set to trip at 200 F [93 C]. Vapor High Limit (LP models only) (PN ) The vapor high limit is wired in series with the circuit. It serves as a safety interlock and shuts down the burner in case of high vapor temperature at the vaporizer coil. This high limit is set to trip at 160 F [71 C]. Vaporizer Coil (LP models only) (PN ) The vaporizer coil is a piece of rolled schedule 80 pipe that allows liquid propane to expand into a vapor that will burn at the point of ignition. Air Switch (if equipped, PN F148003) The Air Switch can be used as a safety device that proves if there s airflow from the fan. Honeywell Spark Generator (PN ) The Spark Generator is used to provide the actual ignition spark. It's controlled and powered by the Fenwal board. Modulating Valve (MV models only) (¾" - PN ) (1¼" - PN ) A modulating valve is available as an option on LP or natural gas heaters. It automatically adjusts the gas flow to regulate the underbin temperature, thereby maintaining a set temperature. A flexible tube going from the valve to the underbin area is filled with a liquid that expands or contracts with temperature, thus regulating the amount of gas going to the burner. Thermostats or humidistats are not required when using a modulating valve heater. The two terminals on the terminal strip in the heater control box (normally used for the control device) must be jumped for the heater to operate. Monitor temperatures under the bin with a thermometer. Ball Valve (HL models only) (PN ) A ball valve used on the low fire side of the fuel loop establishes the low fire burner setting. Y-Strainer (LP models only) (3/8" - PN ) (½" - PN ) The Y-strainer is installed at the inlet of the

15 control loop to trap contaminants coming from the supply tank or supply line. Remove the pipe plug periodically and clean out the Y-strainer. Ball Valve (LP models only) A ball valve is installed between the Y-strainer and liquid solenoid as a means of manually shutting off the supply of fuel to the burner. Relief Valve (LP models only) (PN F048424) Relief valves are installed to prevent excessive pressure build up at points where gas can be trapped in the fuel line. Push Button Start/Stop Switch (PN F048401) Regulator (LP models only) (PN BY REGO, PN F048404) (BY CASH-ACME PN ) Regulators are used to provide a constant flow of gas at a constant pressure. They are used to adjust the flow of gas to establish a desired operating temperature. As the adjusting screw is turned is turned in, pressure will increase as will gas flow. When the 3/4" vapor solenoid is opened the operating pressure will be indicated by the pressure gauge. Igniter (PN ) The igniter provides spark to the air gas mixture via the spark generator which is controlled by the fenwal module. Spark is present only during the 4-second trial for ignition. The igniter gap should be 3/16" [4.8]. Flame Probe (PN ) When the flame probe senses flame, a signal is sent to the fenwal ignition module indicating it's ok for the solenoid valves to remain open. A small amount of electricity is present in the flame and a flame probe acts as a conductor so that when flame is present the electrical circuit is completed. A minimum of 1 microamp is required at the fenwal board to maintain flame. The actual current may be checked by connecting a microammeter to the FC test pins. Fuse (3.0 amp fuse - PN F048415) (1.0 amp fuse - PN ) 15 A 3.0 amp slow-blow fuse is mounted on the front of the control housing to protect electrical components of the heater. A 1.0 amp fast-acting fuse is included in the wiring harness circuitry to protect the ignition board. When replacing fuses make sure the correct amp-rated fuse is installed. Toggle Switch (Switch - PN ) (Switch boot - PN ) Mounted on the front of the control housing, this switch is used to provide power to the burner and begin the ignition sequence. It is also used to reset the fenwal module should the burner fail to light after three attempts. Power ON Lamp (PN ) SETTING THE DRYING TEMPERATURE Although it is conventional to think of temperature as a gauge to determine the drying process, drying is actually accomplished by delivering BTUs to the crop being dried. BTUs are delivered as a result of air flow (CFM) combined with a heat source which in this case is the gas burner. Plenum temperature indicates how hot it is under the bin, but not the amount of energy being delivered. Adequate air flow is equally important in the drying process. An ideal ratio of air-to-gas is required for proper combustion. CFMs delivered by the fan decreas as static pressure under the drying floor increases (due to a deeper bed depth, foreign material in the grain, or nature of the crop). When CFMs decrease there is less air to mix with the gas. Consequently the amount of fuel going to the burner should be decreased. An excess fuel-to-gas ratio will cause the flame to get long and yellow, resulting in inefficient burn. A good flame should be short, bushy, and blue. If drying is to be done at static pressures in excess of 3.5" [89] of water column, NECO recommends a centrifugal fan and heater be used.

16 The regulator setting determines the amount of heat generated by the burner. (NECO supplies a regulator only with LP heaters; the customer or gas supplier provides a regulator for natural gas heaters). Temperature under the bin is determined by the burner control whether it is a thermostat, humidistat, or a modulating valve. The burners can be operated without a burner control mounted in the drying plenum but is NOT recommended. Excessive temperatures can arise under the drying floor leading to uneven drying, scorched product or fire. Additionally, NECO highly recommends that a thermometer be mounted near the burner control probe under the bin as a safeguard that the burner controls are operating at the desired setting. When operating standard heaters which control the plenum temperature by cycling on and off, try to set the temperature so that heater does not continuously cycle. Attempt to adjust the cycle time between 1½ to 3 minutes. Cycle times will vary with each installation depending on bin size, grain depth, fan size, crop, etc. With the proper air to fuel ratio, a temperature rise of approximately 100 F [38 C] can be expected. Heaters can be operated at a maximum of 20 PSI [138 kpa], but typically operate between 5 and 15 PSI [34 and 103 kpa]. PRE-START CHECK 1. Be sure all electrical and fuel supplies are turned off. 2. Check fan. Make sure fan is free of debris and the fan blades turn freely. Fan guard must be in place. 3. Check heater. Make sure heater is free of debris and all covers are securely in place. Heater must be electrically interlocked with fan. 4. Check bin transition. Make sure transition is free of debris and holes. 5. Make sure the thermostat and or other controls are in place and in working order. 6. Occasionally a high limit switch will trip due to vibration or during shipment. Push red reset button if required. 16 INITIAL START-UP USING PROPANE When propane is the fuel source, the tank should be equipped with a vapor and a liquid tap. The liquid tap should have a rapid flow shut-off valve. In the event of a line break, the rapid flow shut off valve will stop the flow of propane. It is recommended that initial heater start-up each day should be done using the vapor tap. When the heater has run on vapor for 5-10 min., the liquid tap should be opened slowly to avoid tripping the rapid flow shut-off valve. When opening this valve, give it a partial turn to allow the pressure to equalize between the heater and tank before fully opening the valve. After opening the liquid valve, close the vapor valve. Starting on vapor ensures the vaporizer coils are warmed before introducing liquid propane and ensures that only vaporized propane reaches the burner orifice. HEATER OPERATIONS FOR MODELS: 04HC24NGV 04HC24LPV 04HC28NGV 04HC28LPV Prior to starting the heater, make sure all of the start-up procedures have been followed, and that temperature control devices have been wired into the heater. 1. Adjust the plenum thermostat to the desired temperature. The thermostat must be wired into the circuit before the heater will operate. 2. Turn on electrical power to the drying unit. 3. See page 16 "To avoid start-up problems". 4. Push the fan start button. 5. Turn the burner switch to the "ON" position. The fan will now run for approximately for 15 sec. (to purge the drying system) before an ignition will be made by the heater. 6. The heater will attempt to ignite the burner for 4 seconds.*

17 7. Once ignition has been obtained, allow the burner to run for approximately 3 min. Adjust the gas pressure so that the burner is on 75% of the time. Do not exceed 20 lbs. [138 kpa] of gas pressure. 8. Observe plenum temperature through a few cycles to be sure the burner is operating properly. * If the burner fails to ignite after 4 seconds, the unit will wait another 15 seconds before trying a second attempt at ignition. If the burner fails to ignite after three attempts, you must reset the burner by flipping the burner ignition switch off and then back on. The heater will now make three more attempts to ignite. If ignition fails after the second series of attempts, see the trouble shooting section in this manual. HEATER OPERATIONS FOR HI-LO MODELS: 04HL24NGV 04HL24LPV 04HL28NGV 04HL28LPV Prior to starting the heater, make sure all of the start-up procedures have been followed, and that temperature control devices have been wired into the heater. NOTE: Hi-Lo Heaters are continuous-burn devices. NECO highly recommends that you install at least two or three thermometers equally spaced along the circumference of the grain bin plenum. Monitor the drying heat to avoid excessive temperatues. 1. Adjust the plenum thermostat to the desired temperature. The thermostat must be wired into the circuit before the heater will operate. 2. Turn on electrical power to the drying unit. 3. See page 16 "To avoid start-up problems". 4. Push the fan start button. 5. Turn the burner switch to the "ON" position After a 15 second purge cycle the heater will ignite.* 7. Initially set the pressure regulator at a mid range position of between 5 and 10 psi. [34 and 69 kpa] The higher the drying temperature and/ or the colder the ambient conditions, the higher the pressure setting that will be required. 8. After the burner has ignited, do the following which will cause the burner to be on high fire. A. Turn the cycling thermostat to its highest setting. B. Open the ball valve all the way. The ball valve is opened fully when the handle is parallel to the pipe train and is closed when it is perpendicular to the pipe train. 9. Adjust the ball valve so that the burner is in high flame approximately 50% of the time and in low flame 50% of the time. 10. If the burner stays on high fire continuously or does not cycle to low flame frequently enough then there is not enough gas available to satisfy the thermostat setting. To correct this gradually increase the gas pressure. If the burner stays on low flame or does not cycle to high flame frequently enough then the gas pressure is too high and should be gradually reduced. 11. After adjustments are made to the regulator, the ball valve may need to be repositioned so that a frequency of 50% high to low fire is achieved. * If the burner fails to light after four seconds, the unit will wait another thirty seconds before trying a second attempt at ignition. If the burner fails to ignite after three attempts, you must reset the burner by flipping the burner ignition switch off and then back on. The heater will now make three more attempts to ignite. If ignition fails after the second series of attempts, see the trouble shooting section in this manual.

18 HEATER OPERATIONS FOR MODULAR VALVE MODELS: 04MV24LPV 04MV28VPV 04MV28LPV 04MV24VPV Prior to starting the heater, be sure to follow all start-up procedures and to wire the temperature control devices into the heater. NOTE: Mod Valve Heaters are continuous-burn devices. NECO highly recommends that you install at least two or three thermometers equally spaced along the circumference of the grain bin plenum. Monitor the drying heat to avoid excessive temperatues. 1. Adjust the plenum thermostat to the desired temperature. The thermostat must be wired into the circuit before the heater will operate. 2. Turn the modulating valve to the minimum setting. 3. Turn the electrical power to the heater ON. 4. See page 16 "To avoid start-up problems". 5. Push the fan start button. 6. Turn the burner switch to the ON position. 7. After a 15 second purge cycle the heater will ignite.* 8. Once ignition has been obtained, allow the burner to run for about thre (3) minutes. Set the gas pressure (at the regulator) to 5 PSI [34 kpa]. a. Determine the desired plenum temperature. b. Using the vapor valve, set the operating pressure at eight (8) psig for propane, or three (3) psig for natural gas. c. Adjust the valve's "T" handle until the bin thermometer maintains the desired plenum temperature. Turn the handle clockwise to get a higher temperature or counterclockwise to get a lower temperature. d. Set the regulator two (2) psig nighter than the Modulating Valve operating condition by turning the Modulating Valve handle two revolutions, adjusting the regulator to the desired pressuer, and then resetting the Modulating Valve to the desired plenum temperature. 10. A plenum thermometer is required to determine the temperature under the bin. 11. If the plenum does not come up to temperature, gradually increase the gas pressure at the regulator. * If the burner fails to ignite after 4 seconds, the unit will wait another 15 seconds before trying a second attempt at ignition. If the burner fails to ignite after three attempts, you must reset the burner by flipping the burner ignition switch off and then back on. The heater will now make three more attempts to ignite. If ignition fails after the second series of attempts, see the trouble shooting section in this manual. Coil adjustments may be needed for all models using liquid propane vaporizers (LPV). 9. Adjust the modulating valve until bin temperature stabilizes. The Modulating Valve maintains a constant plenum temperatuer by allowing more gas to flow to the burner if the plenum temperatue is lower than desired or by restricting the gas flow if the temperature is higher than desired.to set the Modulating Valve, perform the following steps. 18

19 RECOMMENDED DRYING TEMPERATURES Determine the following: the type of crop you'll be drying, the target drying temperature the type of drying system to be used Then refer to the table below for recommended maximum plenum temperatures. As long as moisture is evaporating from the grain, the kernals remain relatively cool; but as the kernals become dry they warm to the drying temperature. Therefore, higher temperatures increase not only the drying rate but also the likelihood of damage to the grain. For optimal results, you must monitor the temperatures in the dryer at all times. Do not automatically set the plenum temperature to the maximum recommended temperature. Grain quality is enhanced when drying is accomplished at lower temperatures. Reduce the drying temperature as grain reaches the target moisture content. Doing so will prevent cracked grain and reduce fire hazard. Be very careful when drying sunflowers as they highly flammable especially the chaff. Do not exceed temperature recommendatiions. Do not let the area around the dryer become cluttered with sunflower residue or chaff. The drying front moves upward from the base of the bin. Therefore, significant overdrying can occur at the base of the bin in the area where the grain isn't being stirred. Table 4. Drying Temperature Recommendations RECOMMENDED DRYING TEMPERATURES OF NON-SEED CROPS (Note A) CROP IN-BIN CONTINUOUS STIR DRYING IN-BIN BATCH Corn 160 F [71 C] 140 F [60 C] 120 F [49 C] Grain Sorghum 160 F [71 C] 140 F [60 C] 120 F [49 C] Wheat 140 F [60 C] 120 F [49 C] 110 F [43 C] Rice 105 F [40 C] 100 F [38 C] 90 F [32 C] Oats 140 F [60 C] 120 F [49 C] 110 F [43 C] Sunflowers 110 F [43 C] 110 F [43 C] 100 F [38 C] Soybeans 120 F [49 C] 120 F [49 C] 110 F [43 C] Pinto Beans 100 F [38 C] 100 F [38 C] 100 F [38 C] Temperature recommendations are based on commercial non-seed crops. 19

20 WIRING DIAGRAMS For wiring diagrams, see the inside of the control box's access panel. 20

21 Drying Precautions MISUSE OF EQUIPMENT COULD START A FIRE GRAIN FIRES CAN CAUSE SERIOUS INJURY OR DEATH! HOW TO PREVENT IN-BIN FIRES Take the following steps to help prevent fires. 1. Make sure the maximum plenum temperature doesn't rise more than 10 F (5 C) higher than the ambient (outside) air. This will help prevent fires and maintain grain quality. 2. Do not combine drying equipment from different companies. NECO heaters are designed to be used with NECO fans only. Safety features built into one company's units may not be properly triggered when attempting to interface with another company's unit. 3. Fines are a huge fire hazard. Keep all areas (including areas under the perforated floors) free from fines. 4. Screen grain before it goes into a bin. This will help prevent buildup of fines. Using a grain spreader will help distribute fines. 5. Make sure floor supports don't block transitions. 6. Use the dryer fan to ventilate the bins before igniting the heater. This will reduce the risk of a fire or explosion from leaking fuel. 7. Make sure a qualified electrician wires the components. Improper wiring can cause fires. If you believe a fire has started, following these safety procedures. 1. Account for the safety of anyone who's been in the vicinity. 2. Shut off gas at the heater and supply tank. Shut off the fan. Call the Fire Department Seal the fan inlet and any other opening to smother the fire. 4. Remove the fan and heater from the transition. Sandbag the transition opening. Flood the bottom of the bin with water up to about 4" (100 mm) above the perforated floor. This will protect the floor supports and may extinguish the fire. 5. Direct water toward the source of the fire. If a fire is in the upper portions of the dryer, insert a long pipe with small holes into the grain and deliver water to the source of the fire. Doing so may help confine the fire but extinguishing a grain bin fire with water is unlikely to occur. Emptying bin is almost always necessary. 6. Take note of neighboring structures and cool them down if necessary. 7. Make sure fuel tanks are cool. Cool them if necessary. REMOVE ALL GRAIN FROM THE BIN TO REACH THE FIRE NEVER ENTER A BIN THAT'S ON FIRE DO NOT CUT HOLES IN BIN TO REMOVE GRAIN WHEN THERE'S A FIRE STAY CLEAR OF FLOWING GRAIN IT CAN BURY A PERSON GRAIN SMOULDERS FOR DAYS! DO NOT RESTART FAN UNTIL ALL GRAIN HAS BEEN REMOVED

22 INSTALLATION AND OPERATION INSTRUCTIONS SERIES V50 FORM JOHNSON CONTROLS, INC. CONTROL PRODUCTS DIVISION 1302 EAST MONROE STREET GOSHEN, IN JOHNSON CONTROLS SERIES V50 SELF-OPERATED MODULATING VALVES For Outdoor Crop Dryer Service APPLICATION These valves control the flow of gas on natural or liquid propane gas-fired, outdoor crop dryers to maintain desired drying air temperature. Changes in air temperature at the sensing bulb cause the valve to modulate the gas supply to the mainburner. CAUTION: Valves are for outdoor crop dryer service only. Not for use on applications of any other kind. All V50 valves are designed for use only as operating devices. Where system closure, improper flow, or loss of pressure due to valve failure can result in personal injury and or loss of property, a separate pressure relief or safety shut-off valve, as applicaable, must be added by the user. OPERATION LIQUID PROPANE GAS APPLICA- TION These valves are normally located on the crop dryer gas manifold between the pressure-regulating valve and the burner orifice. They are used on vapor withdrawal systems or on liquid withdrawal systems using a direct or indirect vaporizer. They should not be used as expansion valves (handling liquid propane) on straight liquid withdrawal systems. A pressure-regulating valve is required to maintain uniform inlet pressure to the V50 modulating valve because the tank pressure varies considerably due to the changes in tank ambient temperature. The recommended setting for the pressure-regulating valve is no higher than 30 psi (207 kpa). As in many instances the outside temperature will not be high enough to provide a regulating valve with pressure above this value. The maximum working pressure for V50 self-operating modulating valves is 30 psi. As the modulating valve provides only a portion of the pressure drop, the maximum firing rate (valve wide open) is determined by the setting of the pressure regulator and the size of the burner orifice. INSTALLATION Follow original equipment manufacturer s installation instructions, if provided. CAUTION: The valve should not be installed on lines where pressure exceeds 30 psi (207 kpa). When there is a possibility of pressures over 30 psi, provide an overpressure or alarm control. The temperature at the sensing bulb must not exceed maximum valve range shown on the nameplate by more than 20 F (10 C). The maximum ambient temperature around the body must not exceed 175 F (79 C). Be sure the valve is installed so the gas flows through the body in the proper direction as indicated by the arrow on the body. On direct- or indirect-fired vaporizer systems in which hot liquid propane gas is flowing through the valve, install the valve with the bellows pointing down. This allows the temperaturesensing element to perform properly. In vapor withdrawal systems, the gas flowing through the valve is cooler than the sensing bulb and valve mounting position is not as important. The temperature sensing bulb should be installed so the capillary end of the bulb is always higher than the plugged end of the bulb (see Figure 9). Figure 7 - V50A Modulating Valve Figure 8 - V50B Modulating Valve If the installation requires that the bulb be in the horizontal position, it is very important to be sure that the word TOP appears at the top or uppermost surface of the bulb (See Figure 10.) CAUTION: Do not kink or sharply bend the capillary tubing. Coil and secure excess capillary if installed where subject to vibration, allowing some slack in capillary to avoid violin string vibrations. Do not allow capillary to rub surfaces where friction can damage the tubing. 22

23 ORIFICE SIZES IN KIT NO. PLG14A-600R ORIFICE SIZE COLOR In. mm CODE Red Yellow Green Blue Aluminum SOLID PLUG Brass Replace this plug with Orifice Plug when bypass is required Orifice plug - See Table for orifice sizes in PLG14A-600R Kit Figure 13 - Internal bypass within the valve. Figure 14 - Typical piping for the V50 Valve. Figure 11 - Capillary end of Bulb is higher than plugged end of Temperature Bulb. Figure 12 - Horizontal Bulb Mounting with Top at top or uppermost surface of Bulb. BYPASS ORIFICE SELECTION These valves have a threaded hole in the internal web of the valve for an internal bypass. (See Figure 13.) They are normally supplied with a solid plug installed in this hole for a complete shutoff. ADJUSTMENT Adjust the valve close-off point by turning the T handle on top of the range spring housing. When the handle is turned in (clockwise) a high bulb temperature is required to close the valve. Turn the handle out (counterclockwise) when a lower temperature is desired. The operator can set the valve to be fully closed at any temperature within its range. The gauge on V50B valves is an integral part of the temperature sensing element and helps the operator make accurate settings. CHECKOUT PROCEDURE Check for gas leaks with a soap solution at the piping connections and around valve gaskets. Check for minimum fire stability; if unstable use the next larger orifice from kit PLG14A-600R. REPLACEMENT PARTS Before leaving the installation, observe at least 3 complete operating cycles to be sure that all components are functioning correctly. Gas pressure through the valve should be verified by an accurate gauge. REPAIRS AND REPLACEMENT The internal parts, orifice plug, diaphragms and sensing elements may be replaced. Other field repairs must not be made. When ordering a replacement valve or sensing element, specify the product number shown on the valve. Replacement parts and valves may be obtained from the nearest Johnson Controls wholesaler. CAUTION: Check all joints for leaks with a soap solution after the valve has been repaired. Five drilled orifice fittings are supplied Valve Plug Size Valve Renewal Diaphragm Kit* Orifice Kit with each valve for field installation, if ½ STT15A-604R DPM16A-600R PLG14A-600R bypass is needed. The bypass orifice ¾ STT16A-603R DPM16A-601R PLG14A-600R is used to maintain a minimum flame 1 STT17A-614R DPM16A-602R PLG14A-600R which will burn even when the closeoff point has been reached. When the 1¼ STT17A-615R DPM16A-602R PLG14A-600R bypass is required, remove the solid * Includes seat, disc, diaphragms and all internal parts to recondition valve. plug and replace it with the proper orifice plug. See selection table. 23

24 TROUBLESHOOTING OF THE FENWAL IGNITION MODULE Input Polarity If the system shuts down after the ignition trial period even though a spark is present and the gas valves are open, check that the input voltage at terminals (L1) and (L2) is neutral. If the polarity is incorrect reverse the position of the leads of the power cord running between the fan and the heater. Make sure a true neutral exists. A poor or nonexistent neutral will cause erratic operation or no operation at all. Improper Grounding If the system shuts down after the ignition trial period even though a spark is present and the gas valves or valves are open, make sure the Fenwal module is properly grounded to the burner and that the burner itself is grounded. This problem is common though it's remedied easily. High Resistance Make sure all terminals make good contact. Clean all corroded contacts and replace any damaged wiring. against the heater. If this happens reposition the electrode. 7. Check the connections on the Honeywell Spark Generator. Valve Malfunction First check the 1 amp fuse. If the fuse continues to blow, you ll need to replace at least one of the solenoid valves (or its coil). If the valve will not open even though there is a spark during the ignition trial, check the valve for an open coil or broken wire. Use a voltage meter to make sure there is a minimum 110V between (V1) and neutral. Erratic Operation Improper placement of the flame probe can lead to nuisance shutdowns. Repositioning the flame probe may be necessary. Connect a DC microammeter in series between the wire going to the flame rod and terminal (S1) on the Fenwal board. The meter should read 1 microamp or higher while sensing a flame. A meter reading below "0" indicates that the leads are reversed. Interchanging the meter leads will correct the polarity. Igniter Malfunction 1. Check for a good ground between Terminal B on the Fenwal module and the ground. 2. Make sure the spark plug gap is set at 3 /16" (0.48 cm) 3. Check the orientation of the igniter. See the Adjustments section of this manual for proper igniter orientation. 4. Replace the igniter if the porcelain is riddled with cracks. 5. Carbon buildup on the igniter electrode may cause arcing on the electrode closest to the igniter base. Cleaning the igniter may cure the problem. If not, replace the igniter. 6. The igniter may arc to a location other than the electrode tip if the igniter shorts out 24

25 HEATER TROUBLESHOOTING GUIDE Problem No Power Cause Solution Open circuit Plug heater into fan receptacle Check for blown fuses at main disconnect Damaged ignition wire Replace Loose connection Re-attach Inadequate Neutral Excess carbon on igniter Make absolutely certain that there is a good neutral. Clean electrode Grounded igniter Make sure igniter is not grounded to burner Cracked /broken igniter porcelein Replace Blown fuse Replace 3 amp slow blow fuse High limit tripped Correct cause and reset Burner high limit bad Replace Vapor high limit bad Replace Burner control malfunctioning Make sure wire harness is plugged into Fenwal module. Make sure burner is calling for heat. Check Check for arc at a point other than electrode tip. Disconnect wires from switch. Perform Continuity test. Disconnect wires from switch. Perform Continuity test. No Spark WARNING Never check for spark without first shutting off the fuel supply and purging all fuel from the system. Purge the fuel system by shutting off the fuel supply, starting at the fan and cycling the burner ignition sequence 2 to 3 times. This will open the solenoids allowing fuel trapped in the plumbing to exit. 25

26 HEATER TROUBLESHOOTING GUIDE cont d Problem Burner will not ignite Cause Solution Wrong igniter gap Gap to 3/16 [4.8] Igniter positioned improperly Inadequate Neutral No Fuel Improper regulator setting See igniter adjustment section of this manual Check for and provide adequate electrical neutral Check tank pressure, make sure valve is open Set regulator 1-5 PSI for LP or 5-15 for NG 1 amp fuse is blown Solenoid not opening Replace fuse Dirty solenoid replace, Solenoid coil defective Temperature controller Control setting too low Defective controller Flame Probe Relocate and/or check connections Static pressure too high Keep static below 3½ water. Inadequate Neutral Flame tripping high limit Check for and provide adequate electrical neutral. Reduce gas pressure Vaporizer high limit tripping Adjust vaporizer away from flame, reduce gas pressure Modulating valve set too high Readjust mod valve Reduce gas pressure High static pressure Open eave hatches and/or remove some grain from bin. Reduce gas pressure Check When solenoids open a click can be heard or by placing your hand on the valve it can be felt 26 Burner operates for only a few seconds Burner operates for only a few minutes Burner flame flucuates over a long period of time (MV heaters only) Burner flame too yellow

27 HEATER TROUBLESHOOTING GUIDE cont d Problem Burner keeps burning after heater is shut off Cause Solution Solenoid sticking open or dirt in valve seal Temperature setting incorrect Turn fuel off at fuel inlet and at tank, replace solenoid and/ or valve Adjust burner control Adjust regulator Burner rate is more than vaporization rate Adjust vaporizer Reduce gas pressure Too small of supply line Regulator set too low Increase gas pressure Inadequate fuel supply Check tank pressure Check Heater shuts off and on too frequently Frost at liquid solenoid Cannot maintain temperature 27

28 MAINTENANCE Disconnect all power before doing maintenance. Beginning of each drying season: 1. Clean out fan and heater housing of any debris. 2. Check wiring of heater. Look for loose connections, bare wires or any rodent damage 3. Check flame probe for cracked insulation 4. Check spark plug for proper gap or excessive carbon buildup (gap set to 3/16")[4.8] 5. Check all plumbing pipes and fittings for leaks or holes, Use a soap solution or a commercial leak detection agent. Warning: Check vaporizer coil for leaks. Do not use if leaks are present or if coil shows signs of excessive corrosion. After drying season: 1. Turn off fuel supply at source. 2. Burn fuel out of lines. 3. Disconnect power to heater. 4. Make sure lids and covers are securely in place. 5. Cover fan inlet to keep out weather and pests. 28

29 Replacement Parts Figure 7. 29

30 Figure 8. 30

31 Liquid Propane Inlet Control Loop, USA & CE, 24" to 28" Models (083491) Replacement Parts Figure 9. 31

32 Liquid Propane Inlet Control Loop, CSA, 24" to 28" Models (081043) Replacement Parts Figure

33 Liquid Propane Inlet Control Loop, USA & CE, 36" to 44" Models (083519) Replacement Parts Figure

34 On-Off Fuel Control Loop for Vaporized Propane, USA & CE, 24" to 28" Models (043193) Replacement Parts Figure

35 On-Off Fuel Control Loop for Vaporized Propane, CSA, 24" to 28" Models (043879) Replacement Parts Figure

36 Hi-Lo Fuel Control Loop for Vaporized Propane, USA & CE, 24" to 28" Models On-Off Control Loop (043193) Hi-Lo add on Control Loop (040911) Replacement Parts Figure

37 Hi-Lo Fuel Control Loop for Vaporized Propane, CSA, 24" to 28" Models On-Off Control Loop (043879) Hi-Lo add on Control Loop (081034) Replacement Parts Figure

38 Modular Valve Fuel Control Loop for Vaporized Propane, USA & CE, 24" to 28" Models (040917) Replacement Parts Figure

39 Modular Valve Fuel Control Loop for Vaporized Propane, CSA, 24" to 28" Models (N.A.) Replacement Parts Figure

40 On-Off Fuel Control Loop for Natural Gas, USA /CSA, 24" to 28" Models (081076) Replacement Parts Figure

41 Hi-Lo Fuel Control Loop for Natural Gas, USA & CE, 24" to 28" Models On-Off Control Loop (081076) Hi-Lo add on Control Loop (040911) Replacement Parts Figure

42 Hi-Lo Fuel Control Loop for Natural Gas, CSA, 24" to 28" Models On-Off Control Loop (N.A.) Hi-Lo add on Control Loop (081034) Replacement Parts Figure

43 Modulating Valve Fuel Control Loop for Natural Gas, USA & CE, 24" to 28" Models (081081) Replacement Parts Figure

44 Modulating Valve Fuel Control Loop for Natural Gas, CSA, 24" to 28" Models (043882) Replacement Parts Figure

45 Hi-Lo Fuel Control Loop for Vaporized Propane, USA & CE 38" to 44" Models (083520) Replacement Parts Figure

46 MANUFACTURED BY NECO A Division of GLOBAL Industries, Inc North 45th Street Omaha, Nebraska TEL: Toll-free (within Nebraska): Toll-free (outside Nebraska): FAX: