UV Sensor Retrofit Installation Installation Manual PNEG-1928 Date: 04-08-14 PNEG-1928
2 PNEG-1928 UV Sensor Retrofit Installation
Table of Contents Contents Chapter 1 Safety...4 Safety Guidelines... 4 Safety Instructions... 5 Chapter 2 UV Sensor Retrofit Installation Tools...7 Chapter 3 Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers...8 Product Description... 8 Sight Tube Assembly Instructions... 9 Sensor Mounting... 10 Wiring Instructions... 11 Operation... 15 Testing... 15 Chapter 4 UV Sensor Retrofit Installation for CSA/CE Portable Dryers...16 Product Description... 16 Sight Tube Assembly Instructions... 17 Sensor Mounting... 18 Wiring Instructions... 19 Operation... 22 Testing... 22 Chapter 5 UV Sensor Retrofit Installation for Tower Dryers...23 Removing the Flame Probe... 23 Installing the Honeywell UV Sensor... 24 Installing the Seimens UV Sensor... 25 Installing the Protectifier UV Sensor... 26 Chapter 6 Warranty...27 PNEG-1928 UV Sensor Retrofit Installation 3
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 WARNING CAUTION NOTICE DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. 4 PNEG-1928 UV Sensor Retrofit Installation
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 procedures and some problems that 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. Read and Understand Manual 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. Electric Shock Hazard PNEG-1928 UV Sensor Retrofit Installation 5
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. Explosive Gases 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. Keep Emergency Equipment Quickly Accessible Wear Protective Clothing Wear close-fitting clothing and safety equipment appropriate to the job. Eye Protection Remove all jewelry. Tie long hair up and back. Gloves Wear safety glasses at all times to protect eyes from debris. Wear gloves to protect your hands from sharp edges on plastic or steel parts. Wear steel-toed boots to help protect your feet from falling debris. Tuck in any loose or dangling shoestrings. Steel-Toed Boots Respirator A respirator may be needed to prevent breathing potentially toxic fumes and dust. Wear a hard hat to help protect your head. Wear appropriate fall protection equipment when working at elevations greater than six feet (6'). Hard Hat Fall Protection 6 PNEG-1928 UV Sensor Retrofit Installation
2. UV Sensor Retrofit Installation Tools Tools you will need for this installation: Portable drill 7/8" Hole saw or step bit 1/8" Tip screwdriver Phillips bit 9/64" Drill bit Wirecutter Pipewrench Figure 2A PNEG-1928 UV Sensor Retrofit Installation 7
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers Installing the non-self check UV Sensor for Portable Dryers, Fans and Heaters, Top Dry Fenwal, Ansen and GSI (UVSCAN-1) UVSCAN-1 Parts List Part # Description Qty Part # Description Qty D03-1168 Sensor, Quanta Flame UV Non-Self Check 1 FH-1309 Lock Nut 1/2" with Pipe Threads 3 HF-7621 Quanta Flame Cable: 5' 1 FH-1310 Connector, Cord Heyco #3231 Replace 1 THH-4129 Nipple, 1/2" x 5" SCH 40 Black 1 WR-18GRY Wire, 18 Gauge Grey Stranded 1 D67-0005 Coupler, 1/2" SCH 40 Black 1 WR-18RED Wire, 18 Gauge Red Stranded 120-1 0.5 007-1149-9 Bushing, Reducer 1/2" x 1/8" Hex Black 1 WR-18WHT Wire, 18 Gauge White Stranded 1 GT3-1181 Relay, Base 11 Pin Use with GT3-1182 1 HF-7630 Terminal, 0.25 Insul. Fem. CSA 1 GT3-1182 Relay, Off Delay/One Shot DPDT 120VAC 1 4144 Resistor, CF, 150K, 1/4W, 5% 1 406-2293-8 Din Rail x 3" (Special) 1 PNEG-1928 UV Sensor Retrofit Installation Manual 1 S-2786 Screw, TCSF #8-32 x 3/8" PHP ZN 2 BX-10X10X5 Box, 10X10X5 (Stock Box) 1 Product Description The UV flame detection kit UVSCAN-1 was designed to replace the flame rod or probe that is used on Vision dryer controls that utilize the HF-4624 fenwal flame control board. (See Figure 3A.) This flame controller uses a flame rectification circuit that in certain situations may not work reliably with certain gases. Figure 3A Fenwal Flame Control (HF-4624) (HF-4624 not included) The GSI part # D03-1168 UV flame relay sensor (See Figure 3B on Page 9) is more reliable since it picks up the UV light (in the 180-230 nm) that is naturally emitted in the flame when using LP, natural gas or propane as its fuel. It replaces the flame rod or probe located in the burner and re-produces the expected flame signal to the fenwal board. 8 PNEG-1928 UV Sensor Retrofit Installation
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers Product Description (Continued) Figure 3B UV Flame Sensor Relay (D03-1168) This kit will include all the parts necessary to change the flame rectification sensing to a UV style flame sense. Sight Tube Assembly Instructions Locate 1/2" x 5" nipple (C) and attach the 1/2" coupler (B) to one end of this nipple. Then attach the 1/2" to 1/8" reducer bushing (A) into the 1/2" coupling as shown in Figure 3C. (No sealant is necessary.) A B C Figure 3C Sight Tube Assembly Ref # Part # Description A 007-1149-9 1/2" to 1/8" Reducer bushing B D67-0005 1/2" Coupler C THH-4129 1/2" x 5" Nipple PNEG-1928 UV Sensor Retrofit Installation 9
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers Sensor Mounting The location to mount the sensor is critical in providing reliable flame sense. The sensor needs to have a constant view to the flame of the burner during all burner modes and operations. Typically the best location is just to the right of the inspection window plate as shown in Figure 3D. The sensor tube needs to be pointing between the burner veins as shown in Figure 3E. It is best if the sensor points slightly downward to allow any moisture that may be present to drain away from the UV sensor component. Once you have determined the sensors location drill a 7/8" hole into the side of the can and attach the UV sight tube assembly into the hole using two (2) 1/2" lock nuts included with kit. Be sure to leave plenty of thread sticking through the burner can to mount the UV sensor. Figure 3D Outside Sensor Location Figure 3E Sensor Location Pointing between Burner Veins Once UV sensor has been mounted to sight tube then attach the five (5) pin cable to sensor. Route the cable through the black plastic heyco cord connector (FH-1310) then through either an existing hole in the fan/heater control box or drill a new 7/8" hole. Try to keep the cable entrance location close to the relay and fenwal board. Find a location to mount the 3" aluminum din rail and relay base inside the fan/heater control box. Drill two (2) 9/64" holes that will be used to mount the din rail to the heater back panel. Use the two (2) supplied self-tapping phillip screws (S-2786) in the drilled holes to mount the din rail. Once the din rail is secure snap the relay base to the din rail as shown in Figure 3F. Figure 3F Relay Base 10 PNEG-1928 UV Sensor Retrofit Installation
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers Wiring Instructions DANGER Disconnect power and lock out prior to performing this service. The factory and the UV wirings diagram are included (Figure 3H on Page 12 and Figure 3K on Page 14) which will help show the difference between the current and modified versions. 1. Cut the supplied red wire into two (2) equal pieces. Strip the insulation off both ends of each wire. Attach one wire between terminals 10 and 11. Attach the other wire between terminals 5 and 6. 2. Locate the V1 wire on the fenwal board as shown in Figure 3G. Leave the wire connected to the fenwal board and follow it to the terminal strip. Disconnect the wire which will be in terminal number 21 on the terminal strip. Figure 3G Locating the V1 grey wire on the fenwal board and terminal 21. 3. Re-locate the grey wire to the relay base terminal 11 which will also contain a jumper wire between terminals 10 and 11. 4. Strip the insulation off both ends of the supplied grey wire. Attach one end of the grey wire to the terminal number 21 on the terminal strip (where you removed the grey wire above) and attach the other end to the relay base terminal 9. PNEG-1928 UV Sensor Retrofit Installation 11
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers J5-04 12 VDC Positive J5-03 12 VDC Negative J5-02 4-20ma In J5-01 4-20ma Return J4-01 12 VDC Positive J4-02 Extra #1 J4-03 Extra #2 J4-04 Air Switch J4-05 Mercoid J4-06 Grain High-Limit J4-07 Plenum High-Limit J4-08 Vapor High-Limit J4-09 Housing High-Limit J4-10 Fan Overload J3-01 PLENUM SENSOR J3-02 SENSOR GROUND J3-03 GRAIN SENSOR J3-04 SENSOR GROUND LEAVE THIS WIRE INTACT 1 2 3 4 5 6 7 8 9 10 1112 1314 1516 17181920 120 VAC Input Power 120 VAC Neutral 12 Volt DC Negative for Testing 12 Volt DC to Housing High-Limit Housing High-Limit 12 Volt DC Return 12 Volt DC to Vapor High-Limit Vapor High-Limit 12 Volt DC Return 12 Volt DC for Plenum High-Limit Plenum High-Limit 12 Volt DC Return Right Grain High-Limit Yellow Right Grain High-Limit Yellow Left Grain High-Limit Orange Left Grain High-Limit Orange 12 Volt DC to Mercoid (CGA Only) Mercoid 12 Volt DC Return 12 Volt DC to Air Switch Air Switch 12 Volt Return Jumper Grain Temp Sensor Input Temperature Sensor Ground Temperature Sensor Ground Plenum Temp Sensor Input 21 22 23 24 LOCATE V1 WIRE ON FENWAL, DISCONNECT OTHER END OF WIRE FROM TERMINAL STRIP #21 LEAVE OTHER WIRE INTACT THAT RUNS TO J1-01. REMOVE FLAME PROBE WIRE FROM S1 (NO LONGER USED) GREY WIRE COLOR LEGEND GREY WHITE BLACK ORANGE YELLOW PURPLE PINK BROWN RED GREEN BLUE WHITE/BLACK STRIPE LIGHT N.C. V1 L2 V2 L1 B.GROUND S1 FC + FC - J2-05 Fan Power J2-04 AC Neutral J2-03 Burner (L1) Power J2-02 Relay N.O. J2-01 Relay Com J1-04 120 VAC Neutral J1-03 120 VAC Input J1-02 Cycle Solenoid Power J1-01 Fenwal Terminal V1 FENWAL FLAME PROBE Figure 3H Wires to be Moved in Stock Fan/Heater Box (Original Wiring) 12 PNEG-1928 UV Sensor Retrofit Installation
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers Figure 3I Flame Sensor Wire Location 5. Disconnect the flame probe or sensor wire from terminal S1 which is shown in Figure 3I. It is the thin red 18 gauge high temperature wire (Teflon) and tie it back out of the way. Attach the red wire from the UV sensor cable with the spade terminal attached to the S1 terminal of the fenwal. (You may need to peel back more of the grey sheathing of the UV cable to gain more length of the wire conductors to reach all the connection points.) 6. Strip the insulation off both ends of the supplied white wire and insert one end into either terminal 22 or 24 (whichever of the white terminals that contains a single wire) and the other end into terminal 2 of the relay base. 7. Attach the black wire from the UV sensor cable into terminal 2 of the relay base. This will provide the grounding path to the flame signal through neutral. 8. Attach the yellow wire from the UV sensor cable into terminal 1 (black terminal) of the terminal strip in the fan/heater box. 9. Attach the orange wire from the UV sensor cable into terminal 2 (white terminal) of the terminal strip in the fan/heater box. 10. Insert time delay relay into its socket and set the timer using the settings as shown in Figure 3J. Relay terminals: 1 = No Connection 2 = AC Neutral for Relay 3 = No Connection 4 = No Connection 5 = Jumper to 6 6 = Jumper to 5 7 = No Connection 8 = No Connection 9 = To Main Solenoids and V1 Input on Heater Figure 3J Timer Settings and Connections PNEG-1928 UV Sensor Retrofit Installation 13
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers J5-04 12 VDC Positive J5-03 12 VDC Negative J5-02 4-20ma In J5-01 4-20ma Return J4-01 12 VDC Positive J4-02 Extra #1 J4-03 Extra #2 J4-04 Air Switch J4-05 Mercoid J4-06 Grain High-Limit J4-07 Plenum High-Limit J4-08 Vapor High-Limit J4-09 Housing High-Limit J4-10 Fan Overload J3-04 SENSOR GROUND J3-03 GRAIN SENSOR J3-02 SENSOR GROUND J3-01 PLENUM SENSOR J2-05 Fan Power J2-04 AC Neutral J2-03 Burner (L1) Power J2-02 Relay N.O. J2-01 Relay Com J1-04 120 VAC Neutral J1-03 120 VAC Input J1-02 Cycle Solenoid Power J1-01 Fenwal Terminal V1 1 2 3 4 5 6 7 8 9 10 11 12 1314 1516 171819 20 120 VAC Input Power 120 VAC Neutral 12 Volt DC Negative for Testing 12 Volt DC to Housing High-Limit Housing High-Limit 12 Volt DC Return 12 Volt DC to Vapor High-Limit Vapor High-Limit 12 Volt DC Return 12 Volt DC for Plenum High-Limit Plenum High-Limit 12 Volt DC Return Right Grain High-Limit Yellow Right Grain High-Limit Yellow Left Grain High-Limit Orange Left Grain High-Limit Orange 12 Volt DC to Mercoid (CGA Only) Mercoid 12 Volt DC Return 12 Volt DC to Air Switch Air Switch 12 Volt Return TDRSRXP-120V TIMER SETTINGS DIP SWITCH ONE = ON DIP SWITCH TWO = ON DIP SWITCH THREE = ON DIP SWITCH FOUR = ON TURN DIAL TO MAXIMUM (10) TIME DELAY RELAY = GT3-1182 RELAY BASE = GT3-1181 UV SENSOR = D03-1168 TIMER WILL SHUT OFF UV SENSOR EVERY 10 HOURS. 8 9 7 10 6 11 1 5 2 4 3 ORANGE YELLOW BLACK BROWN COLOR LEGEND GREY WHITE BLACK ORANGE YELLOW PURPLE RED A B C D E AC Neutral 120 VAC COM SWITCH NOT Used RECTIFIED OUTPUT PINK BROWN RED GREEN BLUE WHITE/BLACK STRIPE FENWAL Quanta-Flame UV Scanner System Series 5002-01NC LIGHT N.C. V1 L2 V2 L1 B.GROUND S1 FC + FC - Jumper Grain Temp Sensor Input Temperature Sensor Ground Temperature Sensor Ground Plenum Temp Sensor Input 21 22 23 24 Main Solenoid (V1) Main Sol Neutral Cycle Solenoid Cycle Sol Neutral Figure 3K UV Sensor and Relay Wiring 14 PNEG-1928 UV Sensor Retrofit Installation
3. Domestic (USA Models) UV Sensor Retrofit Installation for Portable Dryers Operation The UV sensor is highly sensitive to only UVC light that is present in flame. It can detect a small flame from a lit match over 6' away. Because the particular wavelength C band of UV light this sensor is sensitive to (180-230 nm) is normally absorbed by the ozone present in our atmosphere the sensor will not be affected by normal sunlight. The UV sensor is powered up whenever the dryer controls are energized (orange and yellow wires). The rectified output (black and red wires) of the UV flame sensor is only active when the sensor senses flame through an internal relay. This is provided to the fenwal flame board between terminal S1 and the burner ground or AC Neutral. The time delay relay provides a means of self checking to test whether or not the sensor has possibly burned in a flame sense state. Or in other words the sensor has locked itself up by sensing UV flame even when flame is not present. So every ten (10) hours the timer will open up the internal contacts that provide the flame signal to the Vision Flame board J1-01. This interruption will force the controls to cycle power to the fenwal board in an attempt to relight the burner. Normally, if the UV sensor stops sensing flame then the fenwal will resume by relighting the burner. This will cause a brief interruption in burner flame which will last for about five (5) seconds or so until the next timer relay cycle (ten (10) hours). If the UV sensor has burned in and continues to sense flame even with no flame present then the fenwal board will go into a fault condition and will not allow the burner to relight. If the fenwal has a fault condition then the LED will repeatedly flash two (2) times then pause then flash two (2) times again until power is lost to the fenwal or the controls system shuts down with an error. This will occur after three (3) failed relight attempts to the burner. Life expectancy of the UV sensor is rated for approximately 10000 hours of continuous operation which should provide many years of reliable use. Testing The sensor contains two (2) red LED lamps that will aid in troubleshooting flame sensing issues. One is labeled FLAME STATUS and the other FLAME RELAY. FLAME STATUS indicates the strength of the flame signal. The brighter the LED, the stronger the flames signal. FLAME RELAY turns on once the FLAME STATUS becomes strong enough. This is what activates the flame rectification circuit going to the fenwal board used in the Vision control system. If the sight tube is positioned too close to the spark or the reducing bushing is not used then the flame sensor will falsely sense flame and activate the flame relay. This can be tested by dry firing the burner with the gas turned OFF. You may rarely see the FLAME STATUS light flicker briefly during this test but it should never be strong enough for the flame relay to become active. If everything is working correctly the burner should attempt to relight three (3) times then controls will shut the system down with an ignition failure warning on the screen. NOTE: The ignition source (spark) is very rich in Ultraviolet light. This can cause the UV sensor to sense flame if it can see the light that is emitted from the spark. This is the reason we choked the sight tube down to a 1/8" NPT opening is to reduce this effect. Do not reverse the Yellow and Orange wires on the UV sensor when hooking it up to 120 VAC. The sensor is polarity sensitive and reversing these wires can destroy the sensor. PNEG-1928 UV Sensor Retrofit Installation 15
4. UV Sensor Retrofit Installation for CSA/CE Portable Dryers Installing the CSA/CE self checking UV Sensor for Portable Dryers, Fans and Heaters, Top Dry Fenwal, and Pactrol (UVSCAN-2) UVSCAN-2 Parts List Part # Description Qty Part # Description Qty HF-7620 Sensor, Quanta Flame UV 1 007-1149-9 Bushing, Reducer 1/2" x 1/8" Hex Black 1 HF-7621 Quanta Flame Cable: 5' 1 FH-1309 Lock Nut 1/2" With Pipe Threads 1 THH-4117 Nipple, 1" Close SCH 40 Black 1 FH-1310 Connector, Cord Heyco #3231 Replace 1 GT3-0254 Lock Nut 1" 2 HF-7630 Terminal, 0.25 Insul Fem CSA 2 THH-4138 Bushing, Bell Reducer 1" x 1/2" SCH 40 Black 1 PNEG-1928 UV Sensor Retrofit Installation Manual 1 THH-4129 Nipple, 1/2" x 5" SCH 40 Black 1 BX-10X10X5 Box, 10X10X5 (Stock Box) 1 D67-0005 Coupler, 1/2" SCH 40 Black 1 Product Description The UV flame detection kit UVSCAN-2 was designed to replace the flame rod or probe that is used on Vision dryer controls that utilize the HF-4624 fenwal flame control board used on CSA dryers or D03-0846 Pactrol control used on CE dryers. (See Figure 4A.) These flame controllers uses a flame rectification circuit that in certain situations may not work reliably with certain gases. Figure 4A Fenwal Flame Control (HF-4624) (HF-4624 not included) The GSI part # HF-7620 UV flame relay sensor (See Figure 4B on Page 17) is more reliable since it picks up the UV light (in the 180-230 nm) that is naturally emitted in the flame when using LP, natural gas or propane as its fuel. It replaces the flame rod or probe located in the burner and re-produces the expected flame signal to the fenwal board. 16 PNEG-1928 UV Sensor Retrofit Installation
Product Description (Continued) 4. UV Sensor Retrofit Installation for CSA/CE Portable Dryers Figure 4B UV Flame Sensor Relay (HF-7620) This kit will include all the parts necessary to change the flame rectification sensing to a UV style flame sense. Sight Tube Assembly Instructions Locate 1/2" x 5" nipple (C) and attach the 1/2" coupler (B) to one end of this nipple. Then attach the 1/2" to 1/8" reducer bushing (A) into the 1/2" coupling as shown in Figure 4C. (No sealant is necessary.) A B C Figure 4C Sight Tube Assembly Ref # Part # Description A 007-1149-9 1/2" to 1/8" Reducer bushing B D67-0005 1/2" Coupler C THH-4129 1/2" x 5" Nipple PNEG-1928 UV Sensor Retrofit Installation 17
4. UV Sensor Retrofit Installation for CSA/CE Portable Dryers Sensor Mounting The location to mount the sensor is critical in providing reliable flame sense. The sensor needs to have a constant view to the flame of the burner during all burner modes and operations. Typically the best location is just to the right of the inspection window plate as shown in Figure 4D. The sensor tube needs to be pointing between the burner veins as shown in Figure 4E. It is best if the sensor points slightly downward to allow any moisture that may be present to drain away from the UV sensor component. Once you have determined the sensors location drill a 7/8" hole into the side of the can and attach the UV sight tube assembly into the hole using two (2) 1/2" lock nuts included with kit. Be sure to leave plenty of thread sticking through the burner can to mount the UV sensor. Figure 4D Outside Sensor Location Figure 4E Sensor Location Pointing between Burner Veins Once UV sensor has been mounted to sight tube then attach the five (5) pin cable to sensor. Route the cable through the black plastic heyco cord connector (FH-1310) then through either an existing hole in the fan/heater control box or drill a new 7/8" hole. Try to keep the cable entrance location close to the relay and fenwal board. 18 PNEG-1928 UV Sensor Retrofit Installation
Wiring Instructions 4. UV Sensor Retrofit Installation for CSA/CE Portable Dryers DANGER Disconnect power and lock out prior to performing this service. The factory and the UV wirings diagram are included (Figure 4G on Page 20 and Figure 4H on Page 21) which will help show the difference between the current and modified versions. Figure 4F Flame Sensor Wire Location 1. Disconnect the flame probe or sensor wire from terminal S1 which is shown in Figure 4F. It is the thin red 18 gauge high temperature wire (Teflon) and tie it back out of the way. Attach the red wire from the UV sensor cable with the spade terminal attached to the S1 terminal of the fenwal (CSA models) or to neutral bar of Pactrol control (CE models). (You may need to peel back more of the grey sheathing of the UV cable to gain more length of the wire conductors to reach all the connection points.) 2. Strip the insulation off both ends of the supplied white wire and insert one end into either terminal 22 or 24 (whichever of the white terminals that contains a single wire) and the other end into terminal 2 of the relay base. 3. Attach the black wire from the UV sensor cable into neutral terminal #24. This will provide the grounding path to the flame signal through neutral. 4. Attach the yellow wire from the UV sensor cable into terminal 1 (black terminal) of the terminal strip in the fan/heater box. 5. Attach the orange wire from the UV sensor cable into terminal 2 (white terminal) of the terminal strip in the fan/heater box. PNEG-1928 UV Sensor Retrofit Installation 19
4. UV Sensor Retrofit Installation for CSA/CE Portable Dryers J5-04 12 VDC Positive J5-03 12 VDC Negative J5-02 4-20ma In J5-01 4-20ma Return J4-09 Housing Hi Limit J4-08 Vapor Hi Limit J4-07 Plenum Hi Limit J4-06 Grain Hi Limit J4-05 Mercoid J4-04 Air Switch J4-03 Extra #2 J4-02 Extra #1 J4-01 12 VDC Positive J3-03 Grain Sensor J3-02 Sensor Ground J3-01 Plenum Sensor J3-04 Sensor Ground J4-10 Fan Overload J2-05 Fan Power J2-04 AC Neutral J2-03 Burner (L1) Power J2-02 Relay N.O. J2-01 Relay Com J1-04 120 VAC Neutral J1-03 120 VAC Input J1-02 Cycle Solenoid Power J1-01 Fenwal Terminal V1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 120 VAC Input Power 120 VAC Neutral 12 Volt DC Negatice for Testing 12 Volt DC to Housing High Limit Housing High Limit 12 Volt DC Return 12 Volt DC to Vapor High Limit Vapor High Limit 12 Volt DC Return 12 Volt DC for Plenum High Limit Plenum High Limit 12 Volt DC Return Right Grain High Limit Yellow Right Grain High Limit Yellow Left Grain High Limit Orange Left Grain High Limit Orange 12 Volt DC to Air Switch Air Switch 12 Volt Return Grain Temperature Sensor Input Temperature Sensor Ground Temperature Sensor Ground Plenum Temperature Sensor Input WHITE BLACK ORANGE YELLOW PURPLE GRAY COLOR LEGEND 21 22 23 24 Main Solenoid (V1) Main Solenoid Neutral Cycle Solenoid Cycle Solenoid Neutral PINK BROWN RED GREEN BLUE WHITE/BLACK STR. COFI TRK1-20CU VD IGNITION TRAMSFORMER PRI. 110/120 -.25A - 50/60HZ SEC. 2X14kV AMPL. - 20nA RMS ED 100% MADE IN ITALY 02/09/10 IJF FLAME PROBE RESISTOR L1 PA RESET AIR PROVING SWITCH N N GV1 (V1) (V2) IGNITOR LOCKOUT Pbus COMMS PACTROL B A E C 120 VAC Power Rectified Output COM Switch Quanta-Flame Self Check Scanner System Series 5002 Figure 4G CE UV Sensor Wiring 20 PNEG-1928 UV Sensor Retrofit Installation
4. UV Sensor Retrofit Installation for CSA/CE Portable Dryers J5-04 12 VDC Positive J5-03 12 VDC Negative J5-02 4-20ma In J5-01 4-20ma Return J4-10 Fan Overload J4-09 Housing Hi Limit J4-08 Vapor Hi Limit J4-07 Plenum Hi Limit J4-06 Grain Hi Limit J4-05 Mercoid J4-04 Air Switch J4-03 Extra #2 J4-02 Extra #1 J4-01 12 VDC Positive J3-04 Sensor Ground J3-03 Grain Sensor J3-02 Sensor Ground J3-01 Plenum Sensor J2-05 Fan Power J2-04 AC Neutral J2-03 Burner (L1) Power J2-02 Relay N.O. J2-01 Relay Com 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 JUMPER 120 VAC Input Power 120 VAC Neutral 12 Volt DC Negatice for Testing 12 Volt DC to Housing High Limit Housing High Limit 12 Volt DC Return 12 Volt DC to Vapor High Limit Vapor High Limit 12 Volt DC Return 12 Volt DC for Plenum High Limit Plenum High Limit 12 Volt DC Return Right Grain High Limit Yellow Right Grain High Limit Yellow Left Grain High Limit Orange Left Grain High Limit Orange 12 Volt DC to Mercoid (CGA Only) Mercoid 12 Volt Return 12 Volt DC to Air Switch Air Switch 12 Volt Return J1-04 120 VAC Neutral J1-03 120 VAC Input J1-02 Cycle Solenoid Power J1-01 Fenwal Terminal V1 17 18 19 20 Grain Temperature Sensor Input Temperature Sensor Ground Temperature Sensor Ground Plenum Temperature Sensor Input 21 22 23 24 Main Solenoid (V1) Main Solenoid Neutral Cycle Solenoid Cycle Solenoid Neutral COLOR LEGEND GRAY WHITE BLACK ORANGE YELLOW PURPLE ORANGE YELLOW BLACK BROWN RED AC Neutral 120 VAC COM Switch Not Used Rectified Output PINK BROWN RED GREEN BLUE WHITE/BLACK STRIPE Quanta-Flame UV Scanner System Series 5002-01 NC V1 L2 V2 L1 LIGHT B.GRND S1 FC + FC - A B C D E FENWAL 04/17/13 IJF Figure 4H CSA UV Sensor Wiring PNEG-1928 UV Sensor Retrofit Installation 21
4. UV Sensor Retrofit Installation for CSA/CE Portable Dryers Operation The UV sensor is highly sensitive to only UVC light that is present in flame. It can detect a small flame from a lit match over 6' away. Because the particular wavelength C band of UV light this sensor is sensitive to (180-230 nm) is normally absorbed by the ozone present in our atmosphere the sensor will not be affected by normal sunlight. The UV sensor is powered up whenever the dryer controls are energized (orange and yellow wires). The rectified output (black and red wires) of the UV flame sensor is only active when the sensor senses flame through an internal relay. This is provided to the fenwal flame board between terminal S1 or Pactrol terminal 1 and the burner ground or AC Neutral. If the UV sensor has burned in and continues to sense flame even with no flame present then the self checking feature of the UV sensor will detect this issue and stop sensing flame and shut down the dryer. Life expectancy of the UV sensor is rated for approximately 10000 hours of continuous operation which should provide many years of reliable use. Testing The sensor contains two (2) red LED lamps that will aid in troubleshooting flame sensing issues. One is labeled FLAME STATUS and the other FLAME RELAY. FLAME STATUS indicates the strength of the flame signal. The brighter the LED, the stronger the flames signal. FLAME RELAY turns on once the FLAME STATUS becomes strong enough. This is what activates the flame rectification circuit going to the fenwal board used in the Vision control system. If the sight tube is positioned too close to the spark or the reducing bushing is not used then the flame sensor will falsely sense flame and activate the flame relay. This can be tested by dry firing the burner with the gas turned OFF. You may rarely see the FLAME STATUS light flicker briefly during this test but it should never be strong enough for the flame relay to become active. If everything is working correctly the burner should attempt to relight three (3) times then controls will shut the system down with an ignition failure warning on the screen. NOTE: The ignition source (spark) is very rich in Ultraviolet light. This can cause the UV sensor to sense flame if it can see the light that is emitted from the spark. This is the reason we choked the sight tube down to a 1/8" NPT opening is to reduce this effect. Do not reverse the Yellow and Orange wires on the UV sensor when hooking it up to 120 VAC. The sensor is polarity sensitive and reversing these wires can destroy the sensor. 22 PNEG-1928 UV Sensor Retrofit Installation
Removing the Flame Probe 1. Remove the flame probe (A) from the burner. (See Figure 5A.) 5. UV Sensor Retrofit Installation for Tower Dryers A Figure 5A 2. Cut the wire, leaving enough wire to connect to the new sensor. 3. Install the 1/2" nipple (B) in the location where the flame probe (A) was on the burner. (See Figure 5B.) B Figure 5B Ref # A B Flame Probe 1/2" Nipple Description PNEG-1928 UV Sensor Retrofit Installation 23
5. UV Sensor Retrofit Installation for Tower Dryers Installing the Honeywell UV Sensor 1. Remove the flame probe. (See removing the flame probe on Page 23.) 2. Install the purple Honeywell sensor onto the 1/2" nipple. 3. Install the terminal spade onto the white ground wire on the sensor. 4. Loosen the bolt connecting the current ground wire on the burner. 5. Slide the terminal spade on the sensor ground wire underneath the ground wire on the burner. 6. Re-tighten the bolt. 7. Use the orange connector to connect the blue wire from the sensor to the sensing signal wire that is connected to the control board. 8. Replace the flame sensing amplifier with the UV sensing amplifier. E B C D A Figure 5C Honeywell Sensor - Vision T and F Series and Modular Tower Dryers (UVSCAN-3) Ref # Part # Description Qty A 056-2281-6 Scanner, UV Honeywell 1 B 056-2279-0 Honeywell Amplifier Module - UV 1 C THH-4061 Nipple, 1/2" x 3-1/2" SCH 40 Black 1 D 401176 Connector, Type Orange Ideal - 73B 1 E 1EL0534 Terminal, Spade Panduit #P10-10F-D 1 24 PNEG-1928 UV Sensor Retrofit Installation
Installing the Seimens UV Sensor 5. UV Sensor Retrofit Installation for Tower Dryers 1. Remove the flame probe. (See removing the flame probe on Page 23.) 2. Install the 3/4" reducer onto the 1/2" nipple. 3. Install the silver Seimens sensor onto the 3/4" reducer. 4. Install the terminal spade onto the white ground wire on the sensor. 5. Loosen the bolt connecting the current ground wire on the burner. 6. Slide the terminal spade from the ground wire under the ground wire on the burner. 7. Re-tighten the bolt. 8. Use the orange connector to connect the orange wire from the sensor to the sensing signal wire that is connected to the control board. 9. On the Seimans board, the signal sensing wire must be moved from terminal X10-05-2 to X10-06-1. The burner ground wire must be moved from X10-05-1 to X10-06-2. E A B C D Figure 5D Seimens Sensor - Vision T and F Series Tower Dryers (UVSCAN-4) Ref # Part # Description Qty A GT3-1548 Scanner, UV, Siemens #QRA4.U 1 B D07-0028 Bushing, Reducer 3/4" x 1/2" Hex SCH 40 Black 1 C THH-4061 Nipple, 1/2" x 3-1/2" SCH 40 Black 1 D 401176 Connector, Type Orange Ideal-73B 1 E 1EL0534 Terminal, Spade Panduit #P10-10F-D 1 PNEG-1928 UV Sensor Retrofit Installation 25
5. UV Sensor Retrofit Installation for Tower Dryers Installing the Protectifier UV Sensor 1. Remove the flame probe. (See removing the flame probe on Page 23.) 2. Install the 3/4" reducer onto the 1/2" nipple. 3. Install the green Protectifier sensor onto the 3/4" reducer. 4. Install the terminal spade onto the yellow ground wire on the sensor. 5. Loosen the bolt connecting the current ground wire on the burner. 6. Slide the terminal spade from the yellow ground wire under the ground wire on the burner. 7. Re-tighten the bolt. 8. Use the orange connector to connect the purple wire from the sensor to the sensing signal wire that is connected to the control board. 9. On the Protectifier board, move the signal sensing wire from the bottom connection disk labeled E to the middle connection disk labeled UV. E A B C D Figure 5E Protectifier Sensor - Commercial PLC Tower Dryers (UV SCAN-5) Ref # Part # Description Qty A GT3-0535 Scanner, UV P-C II W W/1/2" Str. Liquid-Tite Connector 1 B D07-0028 Bushing, Reducer 3/4" x 1/2" Hex SCH 40 Black 1 C THH-4061 Nipple, 1/2" x 3-1/2" SCH 40 Black 1 D 401176 Connector, Type Orange Ideal - 73B 1 E 1EL0534 Terminal, Spade Panduit #P10-10F-D 1 26 PNEG-1928 UV Sensor Retrofit Installation
6. Warranty GSI Group, LLC Limited Warranty The GSI Group, LLC ( GSI ) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier. The end-user s sole remedy (and GSI s only obligation) is to repair or replace, at GSI s option and expense, products that in GSI s judgment, contain a material defect in materials or workmanship. Expenses incurred by or on behalf of the end-user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the end-user. Warranty Extensions: The Limited Warranty period is extended for the following products: GSI further warrants that the portable and tower dryer frame and basket, excluding all auger and auger drive components, shall be free from defects in materials for a period of time beginning on the twelfth (12 th ) month from the date of purchase and continuing until the sixtieth (60 th ) month from the date of purchase (extended warranty period). During the extended warranty period, GSI will replace the frame or basket components that prove to be defective under normal conditions of use without charge, excluding the labor, transportation, and/or shipping costs incurred in the performance of this extended warranty. Conditions and Limitations: Product Warranty Period Performer Series Direct Drive Fan Motor 3 Years * Warranty prorated from list price: AP Fans and Flooring All Fiberglass Housings Lifetime 0 to 3 years - no cost to end-user All Fiberglass Propellers Lifetime 3 to 5 years - end-user pays 25% AP and Cumberland Flex-Flo/Pan Feeding System Motors 2 Years 5 to 7 years - end-user pays 50% 7 to 10 years - end-user pays 75% Feeder System Pan Assemblies 5 Years ** Cumberland Feed Tubes (1-3/4" and 2.00") 10 Years * ** Warranty prorated from list price: Feeding/Watering Systems Centerless Augers 10 Years * 0 to 3 years - no cost to end-user Watering Nipples 10 Years * 3 to 5 years - end-user pays 50% Grain Systems Grain Bin Structural Design 5 Years Grain Systems Portable and Tower Dryers 2 Years Motors, burner components and moving parts not included. Farm Fans Portable and Tower Dryer Frames and Portable dryer screens included. Zimmerman 5 Years Internal Infrastructure Tower dryer screens not included. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH ABOVE. SPECIFICALLY, GSI MAKES NO FURTHER WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH: (I) PRODUCT MANUFACTURED OR SOLD BY GSI OR (II) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCTS. GSI shall not be liable for any direct, indirect, incidental or consequential damages, including, without limitation, loss of anticipated profits or benefits. The sole and exclusive remedy is set forth in the Limited Warranty, which shall not exceed the amount paid for the product purchased. This warranty is not transferable and applies only to the original end-user. GSI shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent or distributor. GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which it manufactured. Modifications to products not specifically delineated in the manual accompanying the equipment at initial sale will void the Limited Warranty. This Limited Warranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration, accident or which have been improperly/inadequately maintained. This Limited Warranty extends solely to products manufactured by GSI. Prior to installation, the end-user has the responsibility to comply with federal, state and local codes which apply to the location and installation of products manufactured or sold by GSI. 9101239_1_CR_rev8.DOC (revised January 2014) PNEG-1928 UV Sensor Retrofit Installation 27
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. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.com GSI is a worldwide brand of AGCO Corporation. Copyright 2014 by GSI Group Printed in the USA CN-310047