axial fan heater

AXIAL FAN HEATER
Owner's and Operator's Manual
(CE Models)
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!
August 2010 Printing
Manufactured by
084097
A Division of
GLOBAL Industries, Inc,
9364 North 45th Street
Omaha, Nebraska 68112
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.
LIMITED WARRANTY*
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.
THIS UNDERTAKING IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE.
FAILURE TO FOLLOW THE INSTRUCTIONS
CONTAINED 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.
2
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....................................................................................................................... 10
FUEL SUPPLY...................................................................................................................... 10
LINE SIZING CHART FOR VAPOR PROPANE FUEL.................................................... 11
LINE SIZING CHART FOR LIQUID PROPANE FUEL.................................................... 11
NATURAL GAS............................................................................................................... 13
FENWAL-CONTROLLED HEATER - COMPONENT IDENTIFICATION AND FUNCTION............. 13
SETTING THE DRYING TEMPERATURE...................................................................................... 15
PRE-START CHECK....................................................................................................................... 16
INITIAL START-UP USING PROPANE........................................................................................... 16
HEATER OPERATIONS.................................................................................................................. 16
HEATER OPERATIONS FOR HI-LO MODELS ............................................................................. 17
HEATER OPERATIONS FOR MODULAR VALVE MODELS.......................................................... 18
WIRING DIAGRAMS....................................................................................................................... 19
JOHNSON CONTROLS SERIES V50 SELF-OPERATED MODULATING VALVES ..................... 21
TROUBLESHOOTING OF THE FENWAL IGNITION MODULE..................................................... 23
HEATER TROUBLESHOOTING GUIDE......................................................................................... 24
MAINTENANCE.............................................................................................................................. 27
Replacement Parts................................................................................................................. 28
3
CHECK LIST FOR HEATERS
_______________ 1. ALL WIRE CONNECTIONS SECURED
_______________ 2. SPARK PLUG SECURED - SET GAP @ 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
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.
Unqualified persons are to stay out of the work area. The "Work Area" is defined as the
area surrounding the grain handling equipment.
3.
A person who has not read and understood all operation and safety instructions is NOT
qualified to operate the machine.
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: Customers are responsible for knowing and applying their local
safety regulations.
5
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 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.
NECO highly recommends wearing 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
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 cm2) of
vent area per every 1000 cfm (21 m3/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 1-800-367-6208 OR (402) 453-6912.
7
INSTALLATION DATA AND MOUNTING PAD
Unless otherwise noted [ ] indicates
length measurement in millimeters.
Bin
When installing your heater unit, plan the system such that proper consideration is given to:
1. For even heat distribution. Install heater
in line with the unloading auger as shown in
Figure 1. For more than one heating unit, install
the second heater a minimum of 1½ 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.
Heater
Fan
Unloading
System
SINGLE HEATING UNIT
Bin
BURNER CONTROL
(THERMOSTAT/
HUMIDISTAT)
Fan
Heater
1 1/2 SHEETS MIN.
FOR SECOND
HEATER
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.
Unload System
TWO HEATING UNITS
Figure. 1 Heater Positioning
2. Bin flooring should run at right angles to the
unload auger. Floor supports will then be parallel to the unload auger and offer least resistance to air flow.
3.
IMPORTANT!
Modulating
Probe
Keep under
bin floor.
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.
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: 1. Simultaneous starting 2. Shutters
8
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.
5. Make certain that the bin transition discharge
is of an equal area to your fan outlet. (See the
example in Figure 3 below.)
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" [609.6 mm]
and greater are equipped with cable attachment brackets (located at the handles). Use at
a minimum a 3/16" [4.76 mm] 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.
1. Using the appropriate caulk (caulking rated
at 200° F [93° C]) caulk the Fan/Heater flanges.
Connect the fan to the heater using nuts, bolts
etc. Hand-tighten these fasteners only.
The unit must be securely mounted. If you
choose to mount your fan and heater on a
poured concrete slab, NECO recommends that
the slab be about 6" thick [152 mm] and 12"
[305 mm] wider on each side of the fan/heater.
INSTALLATION
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.
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.
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. Axial Discharge Area
9
FUEL SUPPLY
GROUNDING
Your local gas supplier will provide the tank, the
first stage regulator and the necessary connection to the dryer. He should also test the
connections for leaks. Storage tanks must be
located at least 25' [7.62 m] from buildings or
other structures. This may vary depending on
local codes. Check with your gas supplier for
proper code specifications. Care must be taken
to route the supply line in such a manner that
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.
NECO recommends that your fan/heater be connected to a ground rod that is no further than 8' [2.4
m] away. The ground rod should be connected to
the fan control panel with a minimum 6 AWG solid
bare copper wire. The ground rod must be copperclad and 5/8”diameter x 8' long. Install the rod 2'
away 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.
Please contact an electrical parts supplier to purchase ground rods and wires. NECO recommends
the rod not be driven into dry ground. Follow the
steps below to ensure proper rod installation.
The inside of the supply tank must be free of
all dirt and other contaminants. Liquid propane
supply tanks should have the gas supply end of
the tank raised at a level as shown in figure 4.
1. Dig a ditch large enough to hold 1-2 gallons [3.87.6 liters] of water. Fill it with water.
2. Push rod into the water and jab it into the
ground.
3. Jab the rod up & down allowing the water to
work its way down the hole. This technique will
promote a good conductive bond with the surrounding soil. Drive rod completely down.
4. Connect one end of the ground wire to the rod
with an appropriate ground clamp.
5. Connect the other end of the wire to a ground
lug connector inside of the fan control box. The
ground wire should have no splices or breaks.
Don't use insulated wire for grounding purposes.
DO NOT USE supply tanks for propane which
have 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
NECO recommends that previously installed units
be checked for proper grounding.
Vapor Valve
Liquid Valve
Regulator
Tank
Tee
Liquid
To Vaporizer
Oil Contaiminants
10
Figure 4. Propane Supply Tank
IF OIL ENTERS THE HEATER
FUEL SYSTEM THE WARRANTY
ON FUEL TRAIN COMPONENTS
WILL BE VOID
The supply tank should be 1,000 gallon [3785
Liter] capacity and 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 [345-414
kPa] under flow. For natural gas pressure consult your natural gas representative for pressure
available and installation assistance.
The tank should be equipped with a vapor and
liquid tap. NECO recommends that daily initial
heater start-up be performed using the vapor
tap. The liquid tap should have a rapid flow
shut-off valve. If a line breaks, the rapid flow
shut-off valve will stop propane flow. The rapid
flow valve should have a capacity of about 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, turn the excess flow valve
to the full open position. Consult with your
propane supplier for further information.
are used simultaneously or low ambient temperatures 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. The chart
shown in Table 1 showns approximations.
LINE SIZING CHART FOR VAPOR
PROPANE FUEL
The guide for sizing line for vapor between
the liquid propane tank and the heater allowing
pressure drop of 1 PSI [6.9 kPa] can be seen in
Table 2.
LINE SIZING CHART FOR LIQUID
PROPANE FUEL
The guide for sizing line for liquid propane
between the liquid propane tank and heater allowing pressure drop of 1 PSI [6.9 kPa] can be
seen as Table 3.
Table 1 gives the vaporization rate of a 1,000
gallon [3785 Liter] tank at various temperatures when the tank is 25% full. If more heaters
PROPANE VAPORIZATION RATE - 1,000 [3785 Liters] GALLON TANK
Outside Temperature
Vapor Pressure
Volume
Celsius
Fahrenheit
PSI
kPa
Feet /Hour
38
100
190
1310.0
710
3
Fluid Volume
Meter /Hour Gallons/Hour
3
20.1
19.5
Liters/Hour
BTUs/Hour
(000s)
73.8
1,794
32.2
90
165
1137.6
655
18.5
18
68.1
1,656
26.7
80
140
965.3
600
17.0
16.5
62.5
1,518
21.1
70
130
896.3
545
15.4
15.5
58.7
1,380
15.6
60
102
703.3
490
13.9
13.5
51.1
1,240
10
50
86
529.9
455
12.9
12.5
47.3
1,150
4.4
40
72
496.4
382
10.8
10.5
39.7
965
-1.1
30
58
399.9
327
9.3
9
34.1
826
-6.7
20
47
324.1
273
7.7
7.5
28.4
690
-12.2
10
3
255.1
218
6.2
6
22.7
551
-17.8
0
28
193.1
164
4.6
4.5
17.0
413
-23.3
-10
20
137.9
109
3.1
3
11.4
276
Table 1. Propane Vaporization Rate
11
12
2000 [56.6]
2400 [68.0]
2800 [79.3]
3200 [90.6]
6,000
7,000
8,000
3/8"
300 [1136]
27,450
180 [681.3]
16,470
200 [757]
140 [529.9]
280 [1060]
100 [378.5]
9,150
12,810
18,300
13' [4.0]
80 [302.8]
7,320
25,620
20' [6.1]
60 [227.1]
9' [2.7]
36' [10.9]
82' [25.0]
12' [3.7]
17' [5.2]
26' [7.9]
42' 12.8]
81' [24.7]
300' [91.4]
1/2"
10' [3.0]
13' [4.0]
18' [5.5]
28' [8.5]
47' [14.3]
65' [19.8]
97' [29.6]
160' [48.8]
330' [100.6]
3/4"
14' [4.3]
17' [5.2]
29' [8.8.]
56' [17.1]
83' [25.3]
157' [47.9]
354' [107.9]
1410' [430]
5/8"
1/4"
7' [2.1]
11' [3.4]
20' [6.1]
46' [14.0]
182' [55.5]
729' [222.2]
15' [4.6]
33' [10.1]
51' [15.5]
92' [28.0]
205' [62.5]
825' [251.5]
3/8"
13' [4.0]
15' [4.6]
30' [9.1]
37' [11.3]
61' [18.6]
119' [36.3]
187' [57.0]
331' [100.9]
745' [227.1]
1/2"
Line Length - in feet [meters]
26' [7.9]
33' [13.1]
43' [13.1]
64' [19.5]
87' [26.5]
150' [45.7]
200' [61.0]
305' [93.0]
1"
52' [15.8]
60' [18.3]
118' [36.0]
145' [44.2]
240' [73.2]
470' [143.3]
735' [224.0]
3/4"
Schedule 80 Pipe
Table 3. Line Sizing Chart for Liquid Propane Fuel.
329' [100.3]
5,490
20' [6.1]
82' [25.0]
20 [75.7]
1316' [401.1]
1/2"
Copper Tubing - Type K
40 [151.4]
328' [99.9]
9' [2.7]
14' [4.3]
29' [8.8]
98' [44.8]
147' [44.8]
255' [77.7]
3/8"
Schedule 40 Pipe
Table 2. Line Sizing Chart for Vapor Propane Fuel.
10' [3.0]
15' [4.6]
26' [7.9]
53' [16.2]
180' [54.9]
270' [82.3]
5/8"
Line Length - in feet [meters]
LINE SIZING CHART FOR LP - GAS LIQUID
16' [4.9]
55' [16.8]
80' [24.4]
136' [41.5]
286' [87.2]
1/2"
1,830
10 [37.9]
915
9' [2.7]
15' [4.6]
26' [7.9]
53' [16.2]
89' [27.1]
192' [58.5]
3/8"
Copper Tubing
3,660
Gallons / Hour
[liters / Hour]
BTU per hour
(1,000s)
LP Vapor
Flow Rate
1600 [45.3]
600 [17.0]
1,500
5,000
400 [11.8]
1,000
4,000
200 [5.7]
500
1200 [34.0]
160 [4.5]
400
3,000
120 [3.4]
300
800 [22.7]
80 [2.3]
200
1000 [28.3]
60 [1.7]
150
2,000
40 [1.1]
100
2,500
Feet3 [meter3]
per minute
BTU per hour
(1,000s)
LP Vapor
Flow Rate
LINE SIZING CHART FOR LP - GAS VAPOR
177' [53.9]
204' [62.2]
399' [121.6]
491' [149.7]
813' [247.8]
1"
93' [28.3]
115' [35.0]
155' [47.2]
213' [64.9]
319' [97.2]
336' [102.4]
1-1/4"
785' [239.3]
1-1/4"
190' [57.9]
245' [74.7]
328' [99.9]
449' [136.8]
1-1/2"
---
628' [191.4]
809' ]246.6]
1054' [321.3]
2"
CAUTION: IF THE HEATER
IS TO BE CONNECTED TO A
PORTABLE PROPANE TANK,
THE WHEELS ON THE
TANK MUST BE SECURELY
BLOCKED
When operating propane fueled heaters in very
cold weather, the heater may not be able to
obtain sufficient fuel to reach desired operating
temperature. This is due to very low propane
vapor pressure at cold temperatures. To overcome this situation, the tank can be warmed by
using an electric warming blanket that's been
approved for such a purpose.
CAUTION: EXTREME CARE
MUST BE EXERCISED
WHEN DOING THIS. NEVER USE AN OPEN FLAME
DIRECTLY ON THE TANK
AVOID START-UP PROBLEMS BY HEEDING THE
FOLLOWING ADVICE
1) NECO LP model heaters need propane
vapor for start-up.
2) NECO recommends the supply tank be fitted with both a vapor and liquid tap. A short
line should come out of each tap and meet
at a “T” which 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 the heater and let it run for at least five
minutes.
5) At the tank slowly crack 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. Be
careful not to 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 (though with more difficulty) on the
liquid tap.
7) Start the fan. Very slowly open the liquid tap
allowing just enough propane to vaporize
naturally and build up a few pounds of pressure. Start the heater. Startup may entail
trial-and-error depending on weather condi13
tions. Allow only a small amount of liquid
to vaporize. Do not throw open the valve,
since this will cause flood the fuel loop.
8) If the heater is flooded by liquid propane,
shut off the tank supply. Open the 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.
NATURAL GAS
When using natural gas, your gas company
will install a customer-supplied 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 installation assistance.
FENWAL-CONTROLLED HEATER
COMPONENT IDENTIFICATION AND
FUNCTION
Fenwall ignition module
The ignition module controls the sequence
of events leading to ignition and monitors the
flame during operation. After power is applied
to the burner with the toggle switch, the Fenwal
module has a 15-second purge cycle. At completion of the purge cycle the ignition module
sends power to the vapor solenoid (liquid solenoid on LP models) causing the spark generator
to spark for 4 seconds. If during this 4 seconds
the flame probe senses flame, the solenoid
valve(s) will remain open. If no flame is detected the solenoid valve(s) will close (stopping
the flow of gas). The burner will attempt to light
itself three times before locking out. Consult
the troubleshooting section if lockout occurs. To
reset the ignition module turn the toggle switch
to the off position and then back to the ON position to restart the ignition sequence.
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).
Vapor solenoid valve - ¾"
On LP models except the Hi-Lo option this
valve controls the flow of gas between the
regulator and the burner. It's opened during the
ignition sequence.
Liquid solenoid - 3/8"
This valve is provided on all LP models and
controls the flow of liquid propane before it gets
to the vaporizer. This valve opens during the
ignition sequence and remains open during
operation.
On natural gas models this valve controls the
flow of gas between the customer-supplied
regulator and burner. It's opened during the
ignition sequence.
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).
Fenwall ignition module
This module controls the sequence of events
leading to ignition and monitors the flame during operation. After power is applied to the
burner with the toggle switch, the Fenwal
module purges for 15 seconds. After the purge
cycle, the ignition module sends power to the
vapor solenoid (liquid solenoid on LP models) causing the spark generator to spark for
4 seconds. If during this 4 seconds the flame
probe senses flame, the solenoid valve(s) will
remain open. If no flame is detected the solenoid valve(s) will close, stopping the gas flow.
The burner attempts to light three times before
locking out. Consult the troubleshooting section
if lockout occurs. To reset the ignition module
turn the toggle switch to OFF and then back ON
to restart the ignition sequence.
Vapor solenoid valve - ¾"
On LP models except the Hi-Lo option this
valve controls the flow of gas between the regulator and the burner and is opened during the
ignition sequence.
On natural gas models this valve controls the
flow of gas between the customer supplied
regulator and burner and is opened during the
ignition sequence.
Pressure gage
A pressure gage is provided with all models
with a range of 0-15 PSI [0-100 kPa].
Burner High Limit
The burner high limit is wired in series with the
circuit as a safety interlock to shut down the
burner in case of excessive temperature in the
burner housing. It is set to trip at 200° F (93° C).
Vapor High Limit (LP models only)
The vapor high limit is wired in series with the
circuit as a safety interlock. It will shut 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)
The vaporizer coil is a piece of rolled schedule
80 pipe that allows liquid propane to expand
into a vapor that burns at the point of ignition.
Modulating Valve (MV models only)
A modulating valve is an option on LP or natural
gas heaters. This valve automatically regulates
the gas flow to maintain a desired underbin
temperature. A flexible tube going from the
valve to under the bin is filled with a liquid that
expands or contracts with temperature consequently 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. Use a thermometer to monitor temperatures under the bin.
14
Ball Valve (HL models only)
A ball valve is used on the low-fire side of the
fuel loop to establish the desired low fire burner
setting.
Y-Strainer (LP models only)
The Y-strainer is installed at the inlet of the
control loop to trap contaminants that come
from the supply tank or supply line. The Ystrainer should be cleaned out periodically by
removing the pipe plug.
Fuse
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 solenoid valve circuitry
(this is provided to protect the ignition board).
When replacing fuses be sure to install the correct amp-rated fuse.
Toggle Switch
This switch is mounted on the front of the control housing. It provides power to the burner and
to start the ignition sequence. It is also used to
reset the fenwal module should the burner fail
to light after three attempts.
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)
Relief valves are installed to prevent excessive
pressure build up at points where gas can be
trapped in the fuel line.
Regulator (LP models only)
Regulators provide a constant flow of gas at a
constant pressure. Use them to adjust the flow
of gas to establish a desired operating temperature. As the adjusting screw is turned in, pressure and gas flow will increase. When the ¾"
vapor solenoid is opened the pressure gauge
will indicate the operating pressure.
Igniter
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
When the flame probe senses flame, it sends a
signal to the fenwal ignition module indicating
it's ok for the solenoid valves to remain open.
Because a small amount of electricity is present in the flame a flame probe acting as a conductor causes the electrical circuit to be complete. A minimum of 1 microamp is required at
the fenwal board to maintain flame. The current
can be measured by connecting a microammeter to the FC test pins.
15
Air Proving Switch
All NECO heaters are equipped with an air
proving switch. This switch is an electrical
switch wired in series with the electrical control
circuit. The switch is normally open unless air
pressure forces the contacts closed. The heater
cannot be started unless the airflow from the
fan activates the airflow switch. If the airflow is
stopped the air proving switch will shut down
the heater immediately. If the air proving switch
cycles off from a lack of air, turn the heater
toggle switch off before restarting the fan.
Transition High Limit Switch (limited number
of models are so equipped)
The transition limit is a thermal switch wired in
series with the burner control circuit. It serves
as a safety interlock and will shut down the
burner. It deenergizes the solenoid valves in
case of temperatures over 200° F (93° C) at the
transition. If the switch has been tripped reset it
by pushing in the red button.
SETTING THE DRYING
TEMPERATURE
Although temperature is often thought of determining the drying process, drying is actually
accomplished by delivering BTU's to the grain.
BTU's are delivered by air flow (CFM) combined with a heat source—in this case, the gas
burner. Plenum temperature is an indication of
how hot it is under the bin, but not how much
PRE-START CHECK
energy is being delivered. Adequate air flow is
as important as temperature.
1. Be sure all electrical and fuel supplies are
Proper combustion depends upon an ideal ratio
turned off.
of air-to-gas. As static pressure under the dry2. Check the fan. Make sure the fan is free of
ing floor increases due to a deeper bed depth,
debris, that the fan blades turn freely, and
foreign material in the grain, the compact nature
that a fan guard is in place.
of the grain type, the CFMs delivered by the
3. Check the heater. Make sure the heater is
fan fluctuate. When the CFMs decrease there
free of debris and that all covers are secureis less air to mix with the gas. Consequently,
ly in place. The heater must be electrically
the amount of fuel going to the burner should
interlocked with fan.
be decreased. An excessive fuel-to-gas ratio
4. Check the bin transition. Make sure the
will cause an inefficient burn characterized by a
transition is free of debris and holes.
long, yellow flame. A good flame will be short,
5. Make sure the thermostat and/or other conbushy, and blue. If drying is to be done at static
trols are in place and in working order.
pressures in excess of 3.5" [89] of water col6. Occasionally a high limit switch will trip due
umn, NECO recommends that a centrifugal fan
to vibration or during shipment. Push the
and heater be used.
red reset button if necessary.
The amount of heat generated by the burner is
determined by the regulator setting. (A regulator
is supplied with LP heaters only; the customer
or the gas supplier must provide 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
though this practice is NOT RECOMMENDED.
Excessive temperatures can arise under the
drying floor leading to uneven drying, scorched
product or fire. Additionally, NECO 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 a proper air-to-fuel ratio, you'll see a temperature rise of about 100° F (38° C). Heaters
can be operated at a maximum of 20 PSI [138
kPa], but typically operate between 5 and 15
PSI [34 and 103 kPa].
INITIAL START-UP USING PROPANE
The tank should be equipped with a vapor and
a liquid tap when propane is the fuel source.
The liquid tap should have a rapid flow shutoff valve. If a line breaks the rapid flow shutoff valve will stop the flow of propane. NECO
recommends that the initial heater start-up each
day be performed using the vapor tap. When
the heater has run on vapor for 5 to 10 minutes, the liquid tap should be opened. Open it
slowly to avoid tripping the rapid flow shut-off
valve. When opening this valve, turn it part way
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 the heater 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-CE
04HC24LPV-CE
16
04HC28NGV-CE
04HC28LPV-CE
Before starting the heater perform all the startup procedures and make sure the temperature
control devices have been wired into the heater.
Do the following.
1. Set the plenum thermostat to the desired
temperature. (Make sure the thermostat is
wired into the circuit.)
2. Turn on the electrical power to the drying
unit.
3. Read page 16 "To avoid start-up problems."
4. Push the fan's start button.
5. Turn the burner switch to the "ON" position.
The fan will now run for about 15 seconds
purging the drying system before the heater
makes ignition.
6. The heater will attempt to ignite the burner
for 4 seconds.*
7. When ignition has been obtained, allow the
burner to run for about three minutes. Adjust
the gas pressure so the burner is on 75% of
the time. Do not exceed 20 lb [138 kPa] 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 four seconds,
the unit will wait another 15 seconds before
making a second attempt to ignite. If the burner
fails to ignite after three attempts, reset the
burner by flipping the burner ignition switch off
and then back on. The heater will then make
three more attempts to ignite. If ignition fails
after the second series of attempts, see the
troubleshooting section in this manual.
HEATER OPERATIONS
FOR HI-LO MODELS:
04HL24NGV-CE
04HL24LPV-CE
1. Set 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. Read page 16 "To avoid start-up problems".
4. Push the fan's start button.
5. Turn the burner switch to the "ON" position.
6. 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 to cause the burner to be on high-fire
mode.
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. It is closed when
perpendicular to the pipe train.
9. Adjust the ball valve so that the burner is
in high flame about half the time and in low
flame about half the time.
10. If the burner stays on high fire continuously
or does not cycle to low flame frequently
enough then there won't be enough gas
available to support the thermostat setting.
To correct this situation gradually increase
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 30 seconds before
making a second attempt at ignition. If the
burner fails to ignite after three attempts, reset
the burner by flipping the burner ignition switch
off and then back on. The heater will then make
three more attempts to ignite. If ignition fails
after the second series of attempts, see the
troubleshooting section of this manual.
04HL28NGV-CE
04HL28LPV-CE
Before starting the heater, make sure all startup procedures have been followed, and that
temperature control devices have been wired
into the heater.
17
HEATER OPERATIONS FOR
MODULAR VALVE MODELS:
04MV24LPV-CE
04MV28VPV-CE
04MV28LPV-CE
04MV24VPV-CE
Prior to starting the heater, make sure all 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 the modulating valve to the minimum
setting.
3. Turn on the electrical power to the heater.
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 three minutes.
Set the gas pressure (at the regulator) to 5
PSI [34 kPa].
9. Adjust the modulating valve until bin temperature stabilizes.
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 troubleshooting section in this manual.
Reminder: For all models using liquid propane
(LPV), vaporizer coil adjustments may be necessary.
18
WIRING DIAGRAMS
NECO recommends using the wiring illustrated below. Please refer to your fan's control box for a
more precise wiring diagram.
Figure 5. Wiring Diagram for Hi-Lo Control Box
19
NECO recommends using the wiring illustrated below. Please refer to your fan's control box for a
more precise wiring diagram.
Figure 6. Wiring Diagram for On-Off or Modular Valve Control Boxes
20
INSTALLATION AND OPERATION INSTRUCTIONS SERIES V50 FORM 996-61-4
JOHNSON CONTROLS, INC.
CONTROL PRODUCTS DIVISION
1302 EAST MONROE STREET
GOSHEN, IN 46526
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 APPLICATION
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).
JOHNSON CONTROLS SERIES V50
SELF-OPERATED MODULATING VALVES
For Outdoor Crop Dryer Service
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.
Figure 7 - V50A Modulating Valve
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 temperature- sensing 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).
21
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.
ORIFICE SIZES IN KIT
NO. PLG14A-600R
ORIFICE SIZE
In.
mm
.040
1.02
.062
1.57
.078
1.98
.093
2.36
.125
3.18
SOLID PLUG
COLOR
CODE
Red
Yellow
Green
Blue
Aluminum
Brass
Replace this plug
with Orifice Plug
when bypass is
required
Orifice plug - See
Table for orifice sizes in
PLG14A-600R Kit
Figure 11 - Internal bypass within
the valve.
ADJUSTMENT
Adjust the valve close off point by
turning the “T” handle on top of the
range spring housing.
Figure 9 - Capillary end of Bulb
is higher than plugged end of
Temperature Bulb.
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.
Figure 10 - 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 11.) They
are normally supplied with a solid plug
installed in this hole for a complete shutoff.
Five drilled orifice fittings are supplied
with each valve for field installation, if
bypass is needed. The bypass orifice
is used to maintain a minimum flame
which will burn even when the closeoff point has been reached. When the
bypass is required, remove the solid
plug and replace it with the proper orifice
plug. See selection table.
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.
Figure 12 - Typical piping for the
V50 Valve.
Before leaving the installation,
observe at least three 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 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
valve has been repaired.
REPLACEMENT PARTS
Valve Kit
(Plug Size)
Valve Renewal
Diaphragm Kit
Orifice Kit
½"
STT15A-604R
DPM16A-600R
PLG14A-600R
¾"
STT16A-603R
DPM16A-601R
PLG14A-600R
1"
STT17A-614R
DPM16A-602R
PLG14A-600R
1¼"
STT17A-615R
DPM16A-602R
PLG14A-600R
* Includes seat, disc, diaphrams and all internal parts to recondition valve.
22
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.
Valve Malfunction
First check the 1-amp fuse. If the fuse continues to blow, 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.
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 common problem is remedied easily.
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.
High Resistance
Make sure all terminals make good contact.
Clean all corroded contacts and replace any
damaged wiring.
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
against the heater. If this happens reposition
the electrode.
7. Check the connections on the Honeywell
Spark Generator.
23
24
Replace
Re-attach
Make absolutely certain that
there is a good neutral.
Clean electrode
Damaged ignition wire
Loose connection
Inadequate Neutral
No Spark
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.
Make sure igniter is not
grounded to burner
Replace
Replace 3 amp slow blow fuse
Correct cause and reset
Replace
Replace
Make sure wire harness is
plugged into Fenwal module.
Make sure burner is calling for
heat.
Grounded igniter
Cracked /broken igniter porcelein
Blown fuse
High limit tripped
Burner high limit bad
Vapor high limit bad
Burner control malfunctioning
Excess carbon on igniter
Plug heater into fan receptacle
Check for blown fuses at main
disconnect
Open circuit
No Power
WARNING
Solution
Cause
Problem
HEATER TROUBLESHOOTING GUIDE
Disconnect wires from switch. Perform
Continuity test.
Disconnect wires from switch. Perform
Continuity test.
Check for arc at a point other than electrode
tip.
Check
25
Control setting too low
Defective controller
Igniter positioned improperly
Temperature controller
Check for and provide adequate electrical
neutral.
Reduce gas pressure
Static pressure too high
Inadequate Neutral
Burner operates for only a
few minutes
Readjust mod valve
Reduce gas pressure
Modulating valve set too high
High static pressure
Burner flame flucuates over
a long period of time (MV
heaters only)
Burner flame too yellow
Open eave hatches and/or remove some
grain from bin. Reduce gas pressure
Adjust vaporizer away from flame, reduce
gas pressure
Vaporizer high limit tripping
Flame tripping high limit
Keep static below 3-1/2” water.
Flame Probe
Burner operates for only a
few seconds
1 amp fuse is blown
Solenoid not opening
Improper regulator setting
No Fuel
Relocate and/or check connections
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
Replace fuse
Dirty solenoid replace,
Solenoid coil defective
Wrong igniter gap
Burner will not ignite
Inadequate Neutral
Gap to 3/16”[4.8]
Cause
Problem
Solution
HEATER TROUBLESHOOTING GUIDE cont’d
When solenoids open a click can
be heard or by placing your hand
on the valve it can be felt
Check
26
Temperature setting incorrect
Burner rate is more than vaporiza- Adjust vaporizer
Reduce gas pressure
tion rate
Too small of supply line
Heater shuts off and on too
frequently
Frost at liquid solenoid
Inadequate fuel supply
Cannot maintain temperature Regulator set too low
Solenoid sticking open or dirt in
valve seal
Burner keeps burning after
heater is shut off
Check tank pressure
Increase gas pressure
Turn fuel off at fuel inlet and
at tank, replace solenoid and/
or valve
Adjust burner control
Adjust regulator
Cause
Problem
Solution
Check
HEATER TROUBLE-SHOOTING GUIDE cont’d
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.
27
Replacement Parts
















Figure 13. Basic Replacement Parts.
28




Figure 14. Venturi Burner Replacement Parts
29












Liquid Propane Inlet Control Loop, USA & CE, 24" to 28" Models (083491)
Replacement Parts
Figure 15.
30
Liquid Propane Inlet Control Loop, USA & CE, 36" to 44" Models (083519)
Replacement Parts
Figure 16.
31
On-Off Fuel Control Loop for Vaporized Propane, USA & CE, 24" to 28" Models (043193)
Replacement Parts
Figure 17.
32
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 18.
33
Modular Valve Fuel Control Loop for Vaporized Propane, USA & CE, 24" to 28" Models
(040917)
Replacement Parts
Figure 19.
34
On-Off Fuel Control Loop for Natural Gas, USA & CE, 24" to 28" Models (081076)
Replacement Parts
Figure 20.
35
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 21.
36
Modulating Valve Fuel Control Loop for Natural Gas, USA & CE, 24" to 28" Models (081081)
Replacement Parts
Figure 22.
37
Hi-Lo Fuel Control Loop for Vaporized Propane, USA & CE 38" to 44" Models (083520)
Replacement Parts
Figure 23.
38
Installation & Maintenance Instructions
SERIES
2-WAY INTERNAL PILOT-OPERATED SOLENOID VALVES
8215
NORMALLY CLOSED OPERATION - 3/4I, 1I, 1-1/4I, 1-1/2I OR 2I NPT
Form No.V5996R5
IMPORTANT: See separate solenoid installation and
maintenance instructions for information on: Wiring,
Solenoid Temperature, Causes of Improper Operation, and
Coil Replacement.
DESCRIPTION
Series 8215 valves are 2-way normally closed internal
pilot-operated solenoid valves. Valve bodies are made of
rugged aluminum with trim and internal parts made of steel
and stainless steel. Series 8215 valves may be provided with
a general purpose or explosionproof solenoid enclosure.
OPERATION
Normally Closed: Valve is closed when solenoid is
de-energized; open when energized.
Note: No minimum operating pressure differential
required.
INSTALLATION
CAUTION: Not all valves are approved for fuel gas
service. Check nameplate for correct catalog number,
pressure, voltage, frequency, and service. Never apply
incompatible fluids or exceed pressure rating of the valve.
Installation and valve maintenance to be performed by
qualified personnel.
Future Service Considerations
Provision should be made for performing seat leakage,
external leakage, and operational tests on the valve with a
nonhazardous, noncombustible fluid after disassembly and
reassembly.
Temperature Limitations
For maximum valve ambient and fluid temperatures, refer
to chart below. Check catalog number prefix on nameplate
to determine maximum temperatures.
Construction
AC Construction
DC Construction
Coil
Class
Catalog
Number
Prefix
Max.
Ambient
Temp_F
Max.
Fluid
Temp_F
F
FT
125
125
H
HT
140
140
B
None
or
or
77
77
H
HT
MMIII
Positioning
Valve must be mounted with solenoid vertical and upright.
Piping
Connect piping to valve according to markings on valve
body. Apply pipe compound sparingly to male pipe threads
only. If applied to valve threads the compound may enter the
valve and cause operational difficulty. Avoid pipe strain by
properly supporting and aligning piping. When tightening
the pipe, do not use valve or solenoid as a lever. Locate
wrenches applied to valve body or piping as close as possible
to connection point.
CAUTION: To avoid damage to the valve body, DO NOT
OVERTIGHTEN PIPE CONNECTIONS. If Teflon* tape,
paste, spray or similar lubricant is used, use extra care when
tightening due to reduced friction.
IMPORTANT: To protect the solenoid valve, install a
strainer or filter, suitable for the service involved, in the inlet
side as close to the valve as possible. Clean periodically
depending on service conditions. See ASCO Series 8600,
8601 and 8602 for strainers.
MAINTENANCE
WARNING: To prevent the possibility of
death, serious injury or property damage, turn off
electrical power, depressurize valve, extinguish all
open flames and avoid any type of sparking or
ignition. Vent hazardous or combustible fluid to a
safe area before servicing the valve.
NOTE: It is not necessary to remove the valve from the
pipeline for repairs.
Cleaning
All solenoid valves should be cleaned periodically. The time
between cleanings will vary depending on the medium and
service conditions. In general, if the voltage to the coil is
correct, sluggish valve operation, excessive noise or leakage
will indicate that cleaning is required. In the extreme case,
faulty valve operation will occur and the valve may fail to
open or close. Clean valve strainer or filter when cleaning
the valve.
*Dupont Co. Registered Trademark
All Rights Reserved.
50 Hanover Road, Florham Park, New Jersey 07932
Printed in U.S.A.
www.ascovalve.com
Page 1 of 4
Preventive Maintenance
S Keep the medium flowing through the valve as free from
dirt and foreign material as possible.
S Periodic exercise of the valve should be considered if
ambient or fluid conditions are such that corrosion,
elastomer degradation, fluid contamination build up, or
other conditions that could impede solenoid valve
shifting are possible. The actual frequency of exercise
necessary will depend on specific operating conditions. A
successful operating history is the best indication of a
proper interval between exercise cycles.
S Depending on the medium and service conditions, periodic
inspection of internal valve parts for damage or excessive
wear is recommended. Thoroughly clean all parts. If parts
are worn or damaged, install a complete rebuild kit.
Causes of Improper Operation
S
S
Incorrect Pressure: Check valve pressure. Pressure to
valve must be within range specified on nameplate.
Excessive Leakage: Disassemble valve and clean all
parts. If parts are worn or damaged, install a complete
ASCO Rebuild Kit.
Valve Disassembly
WARNING: To prevent the possibility of
death, serious injury or property damage, turn off
electrical power, depressurize valve, extinguish all
open flames and avoid any type of sparking or
ignition. Vent hazardous or combustible fluid to a
safe area before servicing the valve.
NOTE: Determine valve construction AC (Figure 1 on page
3) or DC (Figure 2 on page 4) then proceed as follows:
1. Remove solenoid enclosure, see separate installation
and maintenance instructions.
2. For AC Construction, unscrew solenoid base
sub-assembly. For DC Construction, unscrew solenoid
base sub-assembly with special wrench adapter
provided in ASCO Rebuild Kit. For wrench adapter
only, order kit No.K218-949. NOTE: For alternate
type open end wrench, order kit No.K168-146-1
which is available for solenoid base sub-assembly
removal or replacement.
3. Remove bonnet screws, valve bonnet, bonnet gasket,
core/diaphragm sub-assembly and body gasket.
4. All parts are now accessible to clean or replace. If parts
are worn or damaged, install a complete ASCO Rebuild
kit.
Valve Reassembly
1.
2.
Lubricate bonnet gasket and body gasket with a light
coat of DOW CORNINGr 200 Fluid lubricant or an
equivalent high-grade silicone fluid.
Apply a light coat of RemGrit TFL 50r Dry Lubricant
to:
S Valve seat
S Valve body flange where diaphragm assembly
contacts the valve body and body gasket.
S
Internal surface of valve bonnet where
diaphragm assembly contacts bonnet when
valve is in the energized (open position).
IMPORTANT: If valve has been disassembled for inspection
and cleaning only and a Rebuild Kit is not being installed,
lubricate the following with RemGrit TFL 50r Dry Lubricant:
S
S
S
Diaphragm assembly on both sides.
MainĂdisc base of core/diaphragm sub-assembly.
Pilot disc at base of core assembly.
CAUTION: Do not distort hanger spring between core
assembly and diaphragm assembly when lubricating pilot
disc.
3. Replace body gasket and core/diaphragm sub-assembly
with closing spring attached. Locate bleed hole in
core/diaphragm sub-assembly approximately 30_ from
the valve inlet.
4. Replace valve bonnet and bonnet screws (6). Torque
screws in a crisscross manner to 100 ±10 in-lbs [11,3
± 1,1 Nm].
5. For AC construction, replace bonnet gasket and
solenoid base sub-assembly. Torque solenoid base
sub-assembly to 45 ± 5 ft-lbs [61,1 ± 6,8 Nm] For DC
construction refer to separate Solenoid Installation
and Maintenance Instructions" for lubrication
instructions; then install bonnet gasket, housing and
solenoid base sub-assembly. Torque solenoid base
sub-assembly to 30 ± 5 ft-lbs [40,7 ± 6,8 Nm].
6. Replace solenoid (see separate instructions) and make
electrical hookup.
WARNING: To prevent the possibility of death,
serious injury or property damage, check valve for
proper operation before returning to service. Also
perform internal seat and external leakage tests
with a nonhazardous, noncombustible fluid.
7.
8.
Restore line pressure and electrical power supply to
valve.
After maintenance is completed, operate the valve a
few times to be sure of proper operation. A metallic
click signifies the solenoid is operating.
ORDERING INFORMATION
FOR ASCO REBUILD KITS
Parts marked with an asterisk (*) in the
exploded views are supplied in Rebuild Kits.
D When Ordering Rebuild Kits for ASCO Valves,
order the Rebuild Kit number stamped on the valve
nameplate.
+ If the number of the kit is not visible, order by
indicating the number of kits required, and the Catalog
Number and Serial Number of the valve(s) for which they
are intended.
Page 2 of 4
Form No.V5996R5
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Torque Chart
Part Name
Solenoid Base Sub-Assembly
Bonnet Screws
Torque Value
45 ± 5 ft.-lbs
100 ± 10 in-lbs
Torque Value in Newton-Meters
61,1 ± 6,8
11,3 ±1,1
solenoid base
sub-assembly
bonnet gasket
bonnet screw
valve bonnet
bleed hole
core/diaphragm
sub-assembly
Locate bleed hole in
core/diaphragm subassembly approximately
30° from valve inlet
body gasket
CAUTION
Do not damage valve
seat in any manner
valve body
Indicates parts supplied
in ASCO Rebuild Kit.
Figure 1. Series 8215 valves without solenoid, AC Construction.
Form No.V5996R5
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 3 of 4
Torque Chart
Part Name
Solenoid Base Sub-Assembly
Bonnet Screws
Open end wrench
available for
solenoid base
sub-assembly
(order no.
K168-146-1)
Torque Value
30 ± 5 ft-lbs
100 ± 10 in-lbs
Torque Value in Newton-Meters
40,7 ± 6,8
11,3 ±1,1
solenoid base
sub-assembly
Pin holes for special
wrench adapter supplied
in ASCO Rebuild Kit.
For wrench adapter only
order no.K218-949
(standard wrench)
housing
wrenching flat
bonnet screw
1/2INPT conduit
connection
bonnet gasket
valve bonnet
bleed hole
Locate bleed hole in
core/diaphragm subassembly approximately
30 °from valve inlet
Indicates parts supplied
in ASCO Rebuild Kit.
core/diaphragm
sub-assembly
body gasket
CAUTION
Do not damage valve
seat in any manner
valve body
Figure 2. Series 8215 valves without solenoid, DC Construction.
Page 4 of 4
Form No.V5996R5
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
This page is intentionally left blank.
43
39
www.necousa.com
MANUFACTURED BY
NECO
A Division of GLOBAL Industries, Inc.
9364 North 45th Street
Omaha, Nebraska 68152 USA
TEL: 402-453-6912
FAX: 402-453-0471
44
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