Service Manual Heaters 220491
Contents
1. Switch Automatic Reset 200 F LU Jumper Clip Neutral Purge Delay 50 sec Terminal _ Block Flame Sensing Relay Manual Reset 4 Ignition Transformer Spark Plug Green Light Figure 13 Axial Heater Flame Sensing Circuits Flame Probe 5 an open condition The heater control is wired to check the status of the continuity of the Flame Probe each time the heater is started If the Flame Probe is Probe is in an open condition 10 11 12 Part Number 220491 Bulletin 464S 2 1 2002 Page 35 of 41 the Flame Probe will prevent heater operation Refer to Figure 12 or Figure 13 for a diagram of the flame sensing circuit and make sure all wires are connected according to the information in the appropriate figure A Use a voltmeter and check for continuity across the Flame Probe Check points are labeled 9 amp in Figure 12 or Figure 13 B If no continuity is present 1 Make sure that the Flame Probe has cooled to the ambient temperature If the Flame Probe has cooled down replace the Flame Probe 2 Check the wires to the Flame Probe If they are broken or burnt off replace the Flame Probe wire Flame Sensing Relay isn t completing the circuit A Reset Manual Reset Button B After resetting check the continuity of the contacts of the Flame Sensing Relay labeled 10A amp 10B in Figure 12 or Figure 13 On the top contact points2. 1 5 Amp Fuse 850412 The fuse protects the Heater Control Circuit from excessive current draw Toggle Switch 710970 The Toggle Switch is the heater On and Off switch Slave Relay for High Limit and Flame Probe 756692 The Slave Relay for the High Limit is activated when the High Limit reaches the 230 F 110 C setting temperature The slave relay shuts off the spark and fuel to the burner and maintains the OFF condition until the operator determines the cause of the High Limit reaching the setting temperature With the High Limit cooled the operator will be able to reset the slave relay by turning the heater toggle switch OFF A second slave relay is utilized to prove that the Flame Probe is functioning properly with every trial for ignition If the Flame Probe is functioning properly the relay allows the purge to energize If the Flame Probe is not functioning properly the Slave Relay prevents the initiation of the ignition process High Limit 776443 The High Limit Control is located in the bin plenum When the High Limit reaches a temperature of 230 F 110 C it activates the slave relay to shut off and keep the heater OFF until the operator determines the reason the High Limit was activated Refer to item 3 above Note that the High Limit is not an operating control and the operator must utilize an operating control and set the firing rate for the desired drying plenum temperature The High Limit is a limitin
3. DOWNSTREAM HEATER COMPONENTS n ra Sparkplug and Flameprobe Detail Figure 4 Downstream Heater Components Part Number 220491 Bulletin 464S 2 1 2002 Page 9 of 41 TABLE 1 DOWNSTREAM HEATER CONTROL REPLACEMENT PARTS LIST ITEM PART DESCRIPTION PART NUMBER Parts Common to All Models x 4 aoa O 2 1 ToggleSwitth 1 740970 Vapor Temperature Limit LPGE units only 157200 _ Flame Sensing Relay 753806 Flame Proe 749842 _ ignition Transformer 1 851790 tt 1 144 Pressure Gauge Propane units 851543 __ 14A Pressure Gauge Natural Gas units 71501 21 1 749614 22 roggesSwtchBot 1 742034 23 PurgeDelay 71994 22 Propane Hose 1 756 25 Venturi Air Switeh 4450 __ 26 1 155820 s Optional External Plenum Controls 1 Nylon Humidistat Control Not Shown 850982 Thermostat Control Not Shown 851014 Humidistat Thermostat Control Not Shown 850974 Modulating Valve Propane Not Shown 701862 3 Modulating Valve Natural Gas Not Shown 767954 rl kj Part Number 220491 Bulletin 464S 2 1 2002 Page 10 of 41 TABLE 2 DOWNSTREAM HEATER REPLACEMENT PARTS FOR SPECIFIC MODELS __ _ CH015TNGE CH1015T VPGE CH1015T LPGE CH1015T LPGEM ITEM PART DESCRIPTION PART 4
4. vaporizer from re cracking the propane and causing an oil film to deposit on the burner The Vapor Temperature Limit is set to shut off the heater if the gas from the Vaporizer reaches a temperature of 160 F 71 C The control will allow the heater to re ignite after the Vaporizer cools The Vapor Temperature Limit is only on LPGE Heaters Purge Delay 719914 Purge Delay is a time delay relay used to delay the energizing of the Ignition Transformer and Solenoid Valves for 30 seconds after the heater is turned on to allow for the removal of any raw gas from the heater before ignition is tried The Purge Delay calls for a 30 second delay before ignition regardless of which control turns the heater on Part Number 220491 Bulletin 464S 2 1 2002 Page 20 of 41 Flame Sensing Relay 753806 The Time Delay Relay has a 20 50 second delay and is used to break the circuit to the Purge Delay Solenoid Valves and Ignition Transformer if the Flame Probe does not establish the presence of the flame at the burner The operator is required to manually reset the Flame Sensing Relay before retrying for ignition Flame Probe 749812 The Flame Probe is switch that is sensitive to heat and is used to establish the presence or absence of flame at the burner The Flame Probe is used with the Flame Sensing Relay as the Flame Safeguard Circuit of the heater The switch is opened on temperature rise Solenoid Valves Solenoid Valves are shut off
5. Caldwell Service Policy SERVICE POLICY CALDWELL STANDARD LIMITED WARRANTY DEALERS HAVE THE RESPONSIBILITY OF CALLING TO THE ATTENTION OF THEIR CUSTOMERS THE FOLLOWING LIMITED WARRANTY PRIOR TO ACCEPTANCE OF AN ORDER FROM THE CUSTOMER FOR ANY CALDWELL PRODUCTS Caldwell warrants to the purchaser for use that if any part of the product is proven to be defective in material or workmanship with 2 years from date of original invoice from factory and Caldwell is notified within 15 days after such defect is discovered Caldwell will at company option either replace or repair said part This standard limited warranty does not apply to damage resulting from misuse neglect material wear accident or improper installation or maintenance Said part will not be considered defective if it substantially fulfills performance specifications THE FOREGOING LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF FITNESS FOR PURPOSE AND OF ANY OTHER TYPE WHETHER EXPRESSED OR IMPLIED Caldwell neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said part and will not be liable for incidental or consequential damages THE REMEDIES STATED HEREIN SHALL BE THE EXCLUSIVE REMEDIES AVAILABLE UNDER THIS STANDARD LIMITED WARRANTY CLAIMS UNDER THIS STANDARD LIMITED WARRANTY SHALL BE HANDLED UNDER THE STANDARD SERVICE POLICY Caldwell will not be responsible for any charges i
6. Do not operate units when conditions are such that freezing of the vents could occur HEED THE FOLLOWING WARNING TO PREVENT ROOF AND WALL DAMAGE OF STRUCTURE 1 USE POSITIVE AERATION SYSTEM PUSH SYSTEM 2 MAKE SURE ALL ROOF VENTS ARE SIZED PROPERLY OPEN AND UNOBSTRUCTED 3 IF USING ROOF EXHAUST FANS WIRE ROOF AND SUPPLY FANS TO START SIMULTANEOUSLY OR MAKE SURE ROOF FANS ARE STARTED WHEN SUPPLY FANS ARE STARTED 4 DO NOT OPERATE YOUR AERATION SYSTEM WHEN CONDITIONS EXIST THAT MAY CAUSE ROOF VENT ICING VENT ICING CAN OCCUR WHEN AMBIENT AIR TEMPERATURE IS BELOW 35 F 2 C AND AIR RELATIVE HUMIDITY IS 90 AND ABOVE FOR ANY QUESTION AS TO POSSIBLE ICING CONDITIONS SHUT DOWN THE SYSTEM AND CONTACT YOUR LOCAL WEATHER BUREAU DETERMINE THE AIR FLOW FROM FAN PERFORMANCE CHARTS AT CHART A FREE AIR AND PROVIDE VENTS ACCORDING TO CHART A BIN VENT CONSULT YOUR CALDWELL BBV 2100 EQUIPMENT DEALER FOR AID BBV 19 3000 IN SIZING POWER EXHAUST HGBV 1 75 2670 FANS AND OR ROOF VENTS 16 9 40969 Figure 2 BIN VENT WARNING DECAL Downstream Heater Control Enclosure Components Part Number 220491 Bulletin 464S 2 1 2002 Page 7 of 41 TI E tt toa U ut g By j r 0 Figure 3 Control Enclosure Components For Downstream Heaters Part Number 220491 Bulletin 464S 2 1 2002 Page 8 of 41
7. Heater Maintenance lk lik kilk l ki k eat ea 27 SIGE DOW i Procedure ieee ube ee Guba ea ee Gus ek Gas ede eee dee 28 Downstream Heater Wiring Diagram 29 Axial Heater Wiring Diagram keke keke keke kk kk KK KK 30 Heater Service EW n das 31 38 39 LIST OF FIGURES Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Table Table Table Table NE Ori Go N gt P Co Part Number 220491 Page 2 of 41 Page Typical Serial Number Plate aa a E ake kelle estes 3 Bin Vent Warning Decal n l n ba la l n ba nk n n 6 Downstream Heater Control Enclosure 7 Downstream Heater Component 8 Axial Heater Control Enclosure Components 15 Axial Heater Gompon 16 Flame Probe Adjustment 23 Flame Probe Adjustment 23 LOW Fire M difiGatiOl lt ua 26 Heater Wiring Diagram 29 Heater Wiring Diagram Axial 30 Downstream Heater Pr
8. On liquid propane units liquid and vapor line strainers both should be checked Warranty 1 void if the strainer or screen is removed and not reinstalled after cleaning The burner should be checked to be sure that is not plugged Bugs and wasps can build nests in them Use a piece of wire or drill bit that will fit the holes in the burner To clean the inside of the burner remove from the heater and tap lightly around the burner Then pour the foreign material out of the inlet The venturi of the air switch sensor on Down Stream Centrifugal Heaters or the air switch sensors on Axial Heaters should be checked and make sure it is not plugged Make sure the orifice and pipe are centered in the premix cone It can be knocked out of adjustment Loosen setscrew on heater plumbing bracket adjust orifice and pipe then retighten setscrew Check all plumbing joints for leaks using the soap test Check all wires to see that they are not bare causing a short Mice eat away insulation if protection measures to control rodents aren t taken spark plug flame probe wires Examine and gap spark plug Through wear the spark plug can go out of adjustment Check during operation every two days The gap of the plug should be 1 8 of an inch The flame probe needs to be checked to be sure that it hasn t burnt off due to not adjusting the flame probe in and out of the flame The flame probe can also be broken Check every two days during operation and re
9. PART 4 PART 4 PART 4 Vapor Solenoid Valve 789263 789255 789255 189255 Liquid Solenoid Valve 753863 753863 12 Fuel Line Strainer v 851626 851626 12 Liquid Line Strainer 851634 851634 753905 715003 715003 715003 15 720516 422253 422253 422253 16 Liquid Valve mw mw 714931 744923 752584 752584 1 Valve 716878 716878 oo Bumer rner 175345 175345 175345 175345 po cH 2025 T NGE CH2025T VPGE CH2025T LPGE CH2025T LPGEM ITEM DESCRIPTION PART PART PART PART Vapor Solenoid Valve 789263 789263 789263 789263 9A Liquid Solenoid Valve Wi Sam 753863 753863 12 _ Vapor Fuel Line Strainer 851626 851626 12 Liquid Fuel Line Strainer 951634 851634 775502 715003 715003 715003 15 719328 714881 714881 714881 e Liquid Valve x mw 74949 aa 752584 752584 HT NERE Valve 116878 116878 190422 190422 190422 190422 Part Number 220491 Bulletin 464S 2 1 2002 Page 11 of 41 EXPLANATION OF COMPONENTS FOR DOWNSTREAM HEATER An understanding of the heater operation can be obtained by learning the function of each heater component Refer to Figures 3 and 4 and Tables 1 and 2 while studying the following section The figures illustrate each component Electrical
10. Transformer and Flame Probe Ignition System d LPGEM Type of Fuel to be Utilized Where Natural Gas Fuel Electric NGEM Natural Gas Fuel Electric with Modulating Valve LPGE Liquid Propane Gas Fuel Electric LPGEM Liquid Propane Gas Fuel Electric with Modulating Valve VPGE Vapor Propane Gas Fuel Electric Axial Heater Example CH 28 b 9 Unit Canadian 28 Housing Diameter O T Transformer and Flame Probe Ignition System NGE Type of Fuel to be Utilized Where NGE Natural Gas Fuel Electric NGEM Natural Gas Fuel Electric with Modulating Valve LPGE Liquid Propane Gas Fuel Electric LPGEM Liquid Propane Gas Fuel Electric with Modulating Valve VPGE Vapor Gas Fuel Electric HEATER ACCESSORIES Part Number 220491 Bulletin 464S 2 1 2002 Page 5 of 41 1 A Humidistat Thermostat or Thermostat Humidistat Control is not included with the standard heater They are to be ordered separately A dual Humidistat Thermostat Kit can be ordered so that one control assembly can be used when two heater units are used on the same bin 2 Chief requires using a fuel line strainer in the fuel line just before the fuel enters the heater plumbing line strainer is not provided VPGE units line strainer be obtained from Chief or your gas company CAUTION YOUR WARRANTY COUL
11. controls 27 29 do not function in the same manner as thermostat in a house When the bin plenum controls reach the set point the heater is then shut off the off mode the bin s plenum temperature will drop below the set point of the control due to the rapid air change in the plenum from the fan The controls do not sense the instantaneous change in air temperature but take time to reach the plenum control setting before controlling the heater operation NOTE The firing rate must be set by the operator to make sure excessive temperature is not present in the plenum 30 31 Modulating Valve The Modulating Valve is a non electrical operating control The Modulating Valve is placed in the heater plumbing and controls the amount of fuel burned by the heater depending upon the temperature of the drying air If the temperature of the drying air is lower than the temperature setting of the Modulating Valve the Modulating Valve opens up and more fuel is burned to raise the drying air temperature If the drying air temperature is higher than the temperature setting the Modulating Valve restricts the amount of fuel to the heater The Modulating Valve has an interchangeable by pass orifice to maintain continuous low heat operation regardless of Modulating Valve setting The orifice is interchangeable for establishing lower or higher by pass flow through the Modulating Valve depending on conditions Part Number 220491 Bulletin 464S 2 1 200
12. that leaves only the Flame Sensing Relay to be defective Replace this part V SYMPTOM HIGH LIMIT LIGHT COMES ON Downstream Heater Only 1 4 Fan inlet obstructed A Keep fan screen clean of all foreign material Fan motor failing A Have motor checked to see that it is coming up to full speed See if static pressure is too high Use static pressure gauge A Check to be sure roof vents are open and the openings are sufficient in size B Check floor for plugged holes C Check grain depth moisture content and fines in grain If any of these conditions are high the grain level should be lowered Firing Rate is too high A Reduce the firing rate SYMPTOM HEATER CYCLES WITHOUT ANY EXTERNAL PLENUM CONTROLS USE POWER ON Part Number 220491 Bulletin 464S 2 1 2002 Page 38 of 41 1 Static pressure too high causing Burner Exhaust Limit to cycle the unit Axial Heater Only A Remove vapor temperature limit from the vapor plumbing line If unit continues to 1 cycle check the following The vent area in the bin roof a Are vents open b Is the amount of openings sufficient The firing rate is too high for the application Check the grain depth foreign material and moisture content If these conditions are high the grain level should be lowered 2 The Vaporizer is too hot A Remove vapor thermostat from the vapor plumbing line 1 If cycling stops adjust vaporizer o
13. the fuel and air are mixed and then burned Terminal Block 749614 The Terminal Block is used as a junction block for connecting the lead wires of the various electrical parts Toggle Switch 712034 The Toggle Switch Boot is used to eliminate water entering the heater controls through the Toggle Switch Purge Delay 719914 The Purge Delay is a time delay relay used to delay the energizing of the Ignition Transformer and Solenoid Valves for 30 seconds after the heater is turned on to allow for the removal of any raw gas from the heater before ignition is tried The Purge Delay calls for a 30 second delay before ignition regardless of which control turns the heater on Liquid Propane 715276 The Liquid Propane Hose is used to connect the liquid plumbing line to the inlet of the vaporizer Venturi Air Switch 415661 The Venturi is used to sense the air velocity for the air switch operation Vapor Propane Hose 155820 The Vapor Propane Hose is used to connect the vaporizer to the vapor propane line Part Number 220491 Bulletin 464S 2 1 2002 Page 14 of 41 Optional External Plenum Control Not Shown 27 28 29 Humidistat Control The Humidistat Control is an electrical operating control that is wired into the heater to cycle the heater On and Off with respect to the relative humidity of the drying Humidistat Control is typically set at about 50 60 relative humidity of the drying
14. to see if the air is the problem 1 With the fan running check continuity across the air switch If there is not continuity and the fan is delivering air the problem is in the air switch or in the venturi B Make sure the screen on venturi are not plugged If the fan is working against 4 static pressure or lower the heater should operate The vapor limit switch may be defective LPGE units only A Use voltmeter and check between the two terminal blocks where the vapor limit is attached If there isn t any continuity replace switch Make sure that the vapor limit switch has had sufficient time to cool and automatically reset Thermostat or Humidistat Control May Be Open A Use a voltmeter and check continuity across the terminal block where the 2 leads of the control are connected B If no Continuity is present 1 Check that the control setting to call for heater operation 2 Check that the wires to the control are not broken If either wire is damaged replace the wire 3 Replace entire Thermostat or Humidistat Part Number 220491 Bulletin 464S 2 1 2002 Page 33 of 41 FlomeProbe Flame Switch Automatic Reset 200 F Purge Delay Neutral 30 sec 1 Terminol Sensing Reloy Monuol REset 3 Ignition Tronsformer Spork Plug Figure 12 Downstream Heater Flame Sensing Circuits Part Number 220491 Bulletin 464S 2 1 2002 Page 34 of 41 Probe
15. uses heat from the burner to convert the liquid propane at the vaporizer entrance to vapor propane The burner requires vapor propane for proper operation The vaporizer outlet is connected to the vapor plumbing line by a vapor propane hose The temperature of the vapor plumbing line is sensed by a vapor limit thermostat which will cycle the heater off if the temperature exceeds 160 F 71 At this temperature the vapor plumbing line should be warm to touch If the temperature of the vapor plumbing line 1 too low move the vaporizer into the by loosening the square headed setscrew holding the vaporizer in place adjusting the vaporizer location and retightening the setscrew If the temperature of the vapor plumbing line is too high the vaporizer should be moved out of the flame with the procedure indicated above 3 Adjustment of the Regulator The Regulator should be set at the firing rate required This can be done by first setting the heater to the desired firing rate with the vapor valve then reopening the Vapor Valve and adjusting the Regulator by turning the adjusting screw until the pressure gauge shows the pressure at the desired firing rate pressure When setting the heater at the desired firing rate the operator must take into account the heater size the static pressure the fan is working against the ambient temperature orifice size and fuel used and the type of plenum control Refer to operation instructions for th
16. wanted for heater operation whether the humidistat is calling for heat or not 40 50 F is recommended Set the humidistat and heater according to the humidistat instructions previously given Using the Humidistat Thermostat Control as Thermostat Control only Set the humidistat at 100 relative humidity Then adjust the thermostat and heater controls according to the thermostat instructions given Using the Humidistat Thermostat Control as a combination Set the humidistat and thermostat at the desired operating conditions Then adjust the firing rate of the heater according to the humidistat and thermostat instructions 7 Adjustment of the Modulating Valve used as a Heater Control The Modulating Valve is used to maintain a constant plenum temperature by allowing more gas to flow to the burner if the plenum temperature is lower than desired or by restricting the gas flow if the temperature is higher than desired To set the Modulating Valve use the following procedures 1 2 3 Determine what plenum temperature is desired Using the vapor valve set the operating pressure at eight 8 psig for propane or three 3 psig for natural gas Adjust the T Handle of the valve until the bin thermometer maintains the desired plenum temperature The handle is turned in clockwise to get a higher temperature or out counter clockwise to get a lower temperature Set the regulator two 2 psig higher than the Modula
17. 2 Page 15 of 41 AXIAL HEATER Axial Heater Control Components Figure 5 Axial Heater Control Enclosure Components Part Number 220491 Bulletin 464S 2 1 2002 Page 16 of 41 Axial Heater Components Figure 6 Axial Heater Components Part Number 220491 Bulletin 464S 2 1 2002 Page 17 of 41 TABLE 3 REPLACEMENT PARTS LIST FOR AXIAL CONTROL ITEM PART DESCRIPTION PART NUMBER Parts to Models 1 aoz 710970 711093 712299 CT Vapor Temperature Limit LPGE units only 15720 719914 753806 749812 llgnition Transformer 851790 12 SparkPug 1 854402 2 17 749614 23 Toggle Switch Boot 712034 25 Liquid PropaneHose 1 7526 27 155820 28 BurnerHigh Limit Wire 1 701961 29 SlaveRelay 756692 WG Optional External Plenum Controls Ld 30 Nylon Humidistat Control Not Shown 850982 Thermostat Control Not Shown 851014 Humidistat Thermostat Control Not Shown 850974 Modulating Valve Propane Not Shown 701862 Modulating Valve Natural Gas Not Shown 767954 Part Number 220491 Bulletin 464S 2 1 2002 Page 18 of 41 TABLE 4 REPLACEMENT PARTS FOR SPECIFIC AXIAL MODELS CH18T NGE PE CH18T VPGE CH24T NGE CH24T VPGE Liquid Solenoid Valve Vapor Fuel
18. A Check orifice to be sure it is clean and the correct size is in use B Check burner 1 See that holes are not plugged 2 See that bugs or mice don t plug the tubing of the burner IV SYMPTOM FLAME SENSING RELAY RESET BUTTON POPS OUT 1 If ignition isn t present Refer to Symptom lll if spark is present and gas isn t available Refer to Symptom Il if gas is present and you are lacking spark Ignition is present A Check position of the probe for proper adjustment B Defective flame probe 1 Check the continuity of the Flame Probe When cool the Flame Probe Electrical Circuit should be closed When hot the Flame Probe Electrical Circuit should be open If defective replace the Flame Probe C Check the flame probe wire If defective replace 1 Check wire for bare spots and shorts to ground a Flame probe should not show continuity from either wire to ground 2 Check the two wires in the flame probe wire assembly to see if they are shorting across in the assembly a With the wires removed from the flame probe there should not be any continuity D Defective Flame Sensing Relay POWER ON 1 Shut off gas supply at vapor line valve Push time delay button in Turn on toggle switch and time the Flame Sensing Relay Flame Sensing Relay button should pop out in 20 to 50 seconds If the button doesn t pop out within this time span replace the Flame Sensing Relay 2 and check out okay
19. D BE JEOPARDIZED IF THE HEATER SHOULD MALFUNCTION DUE TO FOREIGN MATERIAL FOUND IN THE HEATER PLUMBING AND THE FUEL SUPPLY LINE DOES NOT HAVE A LINE STRAINER 3 A Caldwell Vaporizer can be ordered and field installed on CH24T VPGE and CHT28 VPGE units to assure a supply of propane vapor to the heater when conditions are such that the supply tank does not supply a sufficient volume of vapor to the unit The vaporizer is a standard part on CH24T LPGE and CH28T LPGE units 4 When wiring a heater to a 460 Volt three phase or 575 volt three phase fan a Step Down Transformer must be used to develop 115 volt single phase 60 cycle power part 717033 SAFETY Before operating unit perform the following checks Part Number 220491 Bulletin 464S 2 1 2002 Page 6 of 41 1 Make sure the fan heater and transition units are bolted securely together Make sure the screen guard is secured in place 2 Make sure the units are wired in compliance with the Canadian Electrical Code and the ground wire is sized large enough to provide lightening protection 3 Make sure the gas supply installation is according to instructions 4 Provide sufficient bin exhaust vents or fans and make sure they are open or operational before starting the drying system The vents are necessary to provide an exhaust for moisture laden air to reduce condensation and to prevent pressurization of the bin above the grain mass causing added load on the bin
20. ER LIGHT Dj AIR PROVING SWITCH E HIGH LIMIT NORMALLY OPEN 230 F 3 HIGH LIMIT RELAY 6 2 WHITE LIGHT H VAPOR TEMP LIMIT 160 F MODELS ONLY 2 JUMPER WIRE 1 REMOVED ON LPGE MODELS J THERMOSTAT HUMIDISTAT OR COMBINATION gt JUMPER WIRE REMOVED FOR FIELD APPLICATION OF THERMOSTAT HUMIDISTAT OR COMBINATION gt 12 M N 0 5 R 52 u FLAMEPRDBE RELAY FLAME SENSING RELAY MANUAL RESET PURGE DELAY 30 SEC FLAME SWITCH AUTOMATIC RESET 200 F VAPOR SOLENOID VALVE LIGUID SOLENGID VALVE MODELS ONLY IGNITION TRANSFORMER SPARK PLUG JUMPER CLIP TERMINAL BLOCK NOTE LES ENTOUREES SE REFERENT AUX RACCORDEMENTS POUR LE RELAIS LETTRES CHIFFRES FUSIBLE 5 AMP CA B INTERRUPTEUR A LEVIER DU RECHAUFFEUR C LUMI RE DE FEU ORANGE INTERRUPTEUR D EPREUVE DE L AIR Ej LA HAUTE LIMITE 230 F gt F RELAIS POUR LA HAUTE LIMITE GJ LUMI RE DE FEU BLANC H TEMPERATURE LIMITE DE LA VAPEUR 1G0 FC7ICXMOLELES LPGE SEULEMENT H gt FIL SAYTEUR 1 SUR LES MODELES _ J THERMOSTAT HUMIDISTAT QU COMBINAISON J FIL SAUTEUR CENLEVE POUR MONTAGE AU CHAMP DU THERMOSTAT HUMIDISTAT DU COMBINAISON x w ty y L RELAIS POUR REGULATEUR DE FLAMME M RELAIS ELEMENT SENSIBLE MANUEL DE RALLUMAGE DE LA FLAMME N LELAI DU PURGE 30 SEC 02 R G
21. ION LACK OF GAS WITH SPARK PRESENT The check to make sure gas is present should be made after all the electrical component checks are made and the electrical controls are confirmed to be functioning properly Note that the purge delay develops a 30 second delay for the solenoids to open Part Number 220491 Bulletin 464S 2 1 2002 Page 36 of 41 1 Lack of gas to heater A Check tank to see if ample pressure is available to start unit 1 Unit requires 35 psig of propane pressure and 10 psig of natural gas available at the unit for start up B Check to see if tank regulator or line going to the unit is blocked 2 Check to see if solenoids are functioning POWER ON A Put your hand on the top of the solenoid and turn the heater toggle switch on and allow 30 seconds for the purge 1 If you feel a click at the top of the solenoid the coil is okay and the solenoid is functioning electrically 2 If there isn t a click the coil is defective Replace B Check solenoid to see if screen is plugged in the solenoid or the diaphragm is defective 1 Unscrew the top of the brass fixture and the screen and diaphragm are located just inside a Be sure to reassemble properly Reversing any parts in the solenoid will cause the solenoid not to function properly b Keep all foreign material out of solenoid 3 Obstruction in the gas line Inspect the line strainers Remove any foreign material found in the screens NOTE FOR NAT
22. Line Strainer Liquid Fuel Line Strainer Liquid Vaporizer _ y J TT Relief Valve Flame Probe Wire 730473 730473 730499 730499 Spark Plug Wire 701979 701979 701987 701987 x CH2TLPGE CH28T NGE CH28T VPGE CH28T LPGE 10 Liquid Solenoid Valve 753863 753863 13 Vapor Fuel Line Strainer 851626 851626 Liquid Fuel Line Strainer 851634 1 851634 17 Orifice 714980 714956 714956 18 LiquidValve 7449 714049 19 Vaporizer 702035 1 102035 20 Pressure Relieve Valve 716878 716878 702332 702357 702357 702357 Probe Wire 730499 730515 730515 730515 Spark Plug Wire 701987 701995 701995 701955 Part Number 220491 Bulletin 464S 2 1 2002 Page 19 of 41 EXPLANATION OF COMPONENTS FOR AXIAL HEATER An understanding of the heater operation can be obtained by learning the function of each heater component Refer to Figures 5 and 6 and Tables 3 and 4 while studying the following section The figures illustrate each component 1 5 850412 fuse protects the Heater Control Circuit from excessive current draw Toggle Switch 710970 The Toggle Switch is the heater On and Off switch Burner Exhaust Limit 711093 The Burner Exhaust Limit located at the end of the housing is an automatic resetting tempera
23. Part Number 220491 ulletin 4645 4645 2 1 2002 SERVICE MANUAL FOR CH1015T CH2025T SERIES HEATERS amp CH18T CH24T CH28T SERIES HEATERS P O Box 848 Kearney 68848 USA Phone 308 237 3186 DIVISION INDUSTRIES INC 308 237 2650 Part Number 220491 Bulletin 464S 2 1 2002 Page 1 of 41 TABLE OF CONTENTS ASEAN OES ONL IMS kosa kosa oh el kaa koya osa kasa hl Sot hl 1 LiSE oF UG AS eax cock oak ak chk es cv eeu 2 List ofi 2 Introduction 3 Model Number Description 4 Heater ACCESSOrES k e ki dek n ee de KE E HESE k re TE KE H dek de He dek de Wed de ek 5 SID 6 Downstream Heater Components kk a K k kk kK KK KK KK KA KA 7 10 Explanation of Downstream Heater 11 14 Axial Heater amp 15 18 Explanation of Heater 19 22 Heater Operational AdjUStMOMtS 222 2 cccceceeeeeeeceeeneceneeeeeceneeeneceneeeneeeeeeeneceneeeeeeeneeentennee 23 26
24. RMOSTAT CHAMP DU THERMOSTAT HUMIDISTAT HUMIDISTAT OR COMBINATION OU COMBINAISON J FLAMEPROBE RELAY J RELAIS POUR R GULATEUR DE FLAMME FLAME SWITCH AUTOMATIC K R GULATEUR DE FLAMME REMISE EN MARCHE RESET 200 F AUTOMATIQUE A200 F 88 C L WHITE LIGHT L LUMIERE DE FEU BLANC 2 FLAME SENSING RELAY MANUAL RESET M RELAIS L MENT SENSIBLE MANUEL DE N PURGE DELAY 30 SEC L U 02 GREEN LIGHT D LUMIERE DE FEU VERT VAPOR SOLENOID VALVE SOUPAPE DE SOLENOIDE POUR VAPEUR R LIQUID SOLENOID VALVE R ELECTROVALVE LIQUIDE MOD LES lt LPGE MODELS ONLY LPGE SEULEMENT S IGNITION TRANSFORMER S TRANSFDRMATEUR D ALLUMAGE SPARK PLUG T BOUGIE 02 JUMPER CLIP U PINCE DU SAUTEUR V TERMINAL BLOCK BLOC TERMINAL Figure 11 Axial Heater Wiring Diagram NOTE 1 WHEN USED WITH 575 460 OR 230 VOLT A STEP DOWN TRANSFORMER MUST BE USED TO DEVELOP 115 VOLT 1 PHASE 60 HZ POWER Part Number 220491 Bulletin 464S 2 1 2002 Page 31 of 41 SERVICE SECTION The following will help you find any problems that may occur in a Caldwell unit and tips for repairing the heater For servicing of electrical systems open the control enclosure Inside the cover you will find a wiring diagram Figure 10 this is the wiring diagram for a Downstream Heater or Figure 11 this is the wiring diagram for an Axial Heater Find the symptoms you are experiencing with your unit and go t
25. ULATEUR DE FLAMME REMISE EN MARCHE AUTOMATIQUE A200 F 88 C SOUPAPE DE SOLENOIDE POUR VAPEUR R gt ELECTROVALVE LIQUIDE MOD LES LPGE SEULEMENT 52 TRANSFORMATEUR D ALLUMAGE T BOUGIE U PINCE DU SAUTEUR BLOC TERMINAL Figure 10 Downstream Centrifugal Heater Wiring Diagram NOTE 1 WHEN USED WITH A 460 VOLT OR A 575 VOLT FAN A STEP DOWN TRANSFORMER MUST BE USED TO DEVELOP 115 VOLT 1 PHASE 60 HZ POWER Part Number 220491 Bulletin 464S 2 1 2002 A FUSE S AMP AC HEATER TOGGLE SWITCH AMBER LIGHT D BURNER EXHAUST LIMIT AUTOMATIC RESET 270 F E BURNER HIGH LIMIT MANUAL MANUAL RESET 160 F AIR PROVING SWITCH VAPOR TEMP LIMIT 160 F LPGE MODELS ONLY BETE BET 3PHASE 460V 3PHASE x 15 V v Page 30 of 41 S75V 3PHASE FUSIBLE 5 INTERRUPTEUR LEVIER DU RECHAUFFEUR LUMIERE DE FEU ORANGE LIMITE D ECHAPPEMENT DU BROLEUR REMISE EN MARCHE AUTOMATIQUE 270 REMISE A ZERO MANUEL POUR La HAUTE LIMITE 160 F DU BRULEUR INTERRUPTEUR D EPREUVE DE L AIR TEMPERATURE LIMITE DE LA VAPEUR 160 F 71 CXMODELES PGE SEULEMENT G1 JUMPER WIRE REMOVED G gt FIL SAUTEUR CENLEV SUR LES MDDELES LPGE DN LPGE MDDELS H THERMOSTAT HUMIDISTAT H THERMOSTAT HUMIDISTAT DU COMBINAISON DR CDMBINATIDN Hy JUMPER WIRE REMOVED FOR FIL SAUTEUR CENLEVE POUR MONTAGE AU FIELD APPLICATION OF THE
26. URAL GAS HEATER GO DIRECTLY TO STEP C WARNING THE CHECKS IN THESE SECTIONS MUST BE MADE WITHOUT ANY SPARK OR FLAME IN THE IMMEDIATE AREA DISCONNECT SPARK PLUG WIRE FROM TRANSFORMER AND EXTINGUISH ANY FLAMMABLE MATERIALS A Remove vaporizer hose where it is attached to the heater liquid solenoid Leave gas supply on Turn toggle switch on and then immediately off 1 If there is very little gas coming out the solenoid the obstruction is in the heater liquid plumbing or in the tank and line coming to the unit a Remove pressure relief valve If there is pressure when the ball valve is open the restriction is the solenoid B Disconnect the vaporizer hose at the vapor regulator with the hose reattached to the heater liquid plumbing Turn on the heater and then immediately turn the heater off Again there should be a large volume of gas coming out the vapor hose 1 If the vapor line strainer is okay the vaporizer must be plugged Replace vaporizer C Obstruction is located in heater vapor plumbing 1 Shut off gate valve and remove the solenoid Turn on switch and open the vapor valve a If gas is present at the point where the solenoid is attached the solenoid must be defective Replace the solenoid b If gas is not present the regulator is defective Replace the regulator 4 Part Number 220491 Bulletin 464S 2 1 2002 Page 37 of 41 If there is gas present at the pressure gauge but the unit lacks gas for ignition
27. air When the relative humidity is higher than the humidistat setting the heater is cycled On and is left on until the relative humidity is below the humidistat setting If the relative humidity of the drying air is less than the humidistat setting the heater is cycled Off until such time that the relative humidity would become greater than the setting of the humidistat The Humidistat Control is for low temperature drying Thermostat Control 851014 The Thermostat Control is an electrical operating control that is wired into the heater to cycle the heater On and Off with respect to the temperature of the drying air The thermostat is set at a desired temperature and if the temperature is higher than the thermostat setting the heater is cycled Off If the drying air temperature is less than the thermostat setting the heater is cycled On and is left on until such time that the drying air temperature is above the thermostat setting Humidistat Thermostat Control 870974 The Humidistat Thermostat Control is an electrical operating control that is wired into the heater to cycle the heater and Off with respect to both the drying air relative humidity and temperature The Humidistat Thermostat Control will cycle the heater on if either the drying air relative humidity is too high or the drying air temperature is too low with respect to the humidity setting or temperature setting of the control NOTE The optional external plenum
28. check for continuity Make sure the Flame Sensing Relay has cooled and then make sure the Manual Reset Button has been reset If the Flame Sensing Relay has been reset a lack of continuity indicates a defective Flame Sensing Relay Replace the Flame Sensing Relay Purge Delay may be defective POWER ON Check power at the terminal labeled 11 on Figure 12 or Figure 13 of Purge Delay After power has been supplied to Purge Delay for 30 seconds power should be present at the terminal labeled 11A of Purge Delay If not replace Purge Delay Check all wires and connections to be sure they are okay and correct See wiring schematics Figures 10 11 12 amp 13 I SYMPTOM NO IGNITION LACK OF IGNITION SPARK GAS PRESENT 1 Transformer is defective POWER ON A Take the cap holding the spark plug wire off and remove the spark plug wire from the transformer With the Transformer energized ground insulated screwdriver and arc to the transformer post where spark plug wire was connected CAUTION DO NOT TOUCH SCREW DRIVER SHAFT 1 If there isn t any arc or less than 1 8 arc replace transformer Spark plug wire is defective POWER A Take wire off spark plug and arc to heater CAUTION DO NOT TOUCH SPARK PLUG WIRE MOUNTING TERMINAL 1 If it does not arc replace wire Spark plug is defective A Check gap of plug Gap is 1 8 B If above steps 1 and 2 check okay replace spark plug II SYMPTOM NO IGNIT
29. dark in color replace B Check fuse and holder 1 Put one lead on each side of the fuse on the fuse holder screws Needle should show continuity through fuse 5 High Limit may be closed DOWNSTREAM HEATER ONLY A Use voltmeter and check for continuity between the two leads going to High Limit housing 1 Leads are attached to No 1 on the terminal block and the No 2 on the terminal block 5a Part Number 220491 Bulletin 4645 2 1 2002 32 of 41 If there is continuity 1 Remove sensor from the bin a Check the switch by putting leads of meter to the two screws that have wires attached The switch should not show continuity Replace switch if defective b switches are okay then the limit wires are making contact with each other Replace damaged wires Burner High Limit and or Burner Exhaust Limit may be open AXIAL HEATERS A Use voltmeter and check for continuity between the two leads going to Burner Limit Channel 1 Leads are attached to No 1 on the terminal block and to the Toggle Switch If there is not continuity Opposite the fuse side 1 Reset high limit button 2 Remove channel from heater a Check each switch individually by putting leads of meter to the two screws that have wires attached The switch should show continuity Replace switch if defective b If switches are okay then the burner limit wire is defective Replace damaged wire Air Switch may be defective A Check
30. e humidistat thermostat or modulating valve 4 Adjustment of the Humidistat Control if used to operate the Heater Set the Humidistat Control at the desired setting typically 50 60 Recommended To obtain even drying adjust the firing rate of the heater unit so that the Humidistat maintains a constant humidity of the drying air The heater should be set at a firing rate of approximately two psi gauge pressure for propane or one psi gauge pressure for natural gas and then adjusted to obtain operation of the heater the majority of the time The heater firing rate must be checked as humidity conditions change 5 Adjustment of the Thermostat Control if used to operate the Heater Set the Thermostat Control to the desired temperature setting Initially set the firing rate of the heater at two psi gauge pressure for propane or one psi gauge pressure for natural gas To obtain even drying adjust the firing rate of the heater unit so that the thermostat calls for heat 90 of the time The heater firing rate must be checked as temperature conditions change WARNING THE PLENUM THERMOSTAT FUNCTIONS AS A DRYING THERMOSTAT NOT AS A PLENUM HIGH LIMIT Part Number 220491 Bulletin 464S 2 1 2002 Page 25 of 41 6 Adjustment of Humidistat Thermostat Control if used to operate the Heater 1 Using the Humidistat Thermostat Control as a Humidistat Control only Set the thermostat at the lower temperature limit This is the temperature
31. ferences in bin setups drying methods and weather climates These adjustments should be checked at least twice a day or after 6 hours of operation to make sure that the heater is functioning properly and that the operator is getting the desired result 1 Adjustment of Flame Probe The Flame Probe should be adjusted so that the Flame Probe does not shut off the heater unnecessarily and also does not prematurely shorten the life of the Flame Probe The Flame Probe is adjusted by loosening up one bolt and rotating the switch closer or farther away from the flame as shown in Figure 7 amp 8 The ideal location of the Flame Probe is when the end of the flame is just barely touching the probe A small dull red area on the probe can identify this ideal location This red area is where the flame is just touching the switch It should be noted that the Flame Probe should be adjusted to the highest heater plumbing pressure at which the heater will be operated If the heater were ever operated at a higher heater plumbing pressure then the Flame Probe would need to be re adjusted SEE DETAIL A DETAIL TOP VIEW Figure 7 Flame Probe Adjustment For Down Figure 8 Flame Probe Adjustment For Axial Stream Heaters Heaters Part Number 220491 Bulletin 464S 2 1 2002 Page 24 of 41 2 Adjustment of the Vaporizer LPGE Heater only The vaporizer is used on LPGE units and is located in the flame established by the burner The vaporizer
32. g device such that the heater is locked off if the 230 F 110 C temperature is obtained Air Switch 785691 The Air Switch is a control that senses the flow of air from the fan to the heater If for any reason the air flow is stopped the Air Switch will shut off the heater The Air Switch will keep the heater shut off until air flow from the fan is re established If the Air Switch cycles off from a lack of air turn the heater toggle switch off before restarting the fan Vapor Temperature Limit LPGE units only 157200 The Vapor Temperature Limit is an automatic resetting temperature limiting control used to protect the Solenoid Valve and Regulator from being damaged due to excessive gas temperature coming from the vaporizer Also the Vapor Temperature Limit protects the vaporizer from re cracking the propane and causing an oil film to deposit on the burner The Vapor Temperature Limit is set to shut off the heater if the gas from the Vaporizer reaches a temperature of 160 F 71 C The control will allow the heater to re ignite after the Vaporizer cools The Vapor Temperature Limit is only on LPGE Heaters Part Number 220491 Bulletin 464S 2 1 2002 Page 12 of 41 Flame Sensing Relay 753806 The Flame Sensing Relay has a 20 50 second delay and is used to break the circuit to the Purge Delay Solenoid Valves and Ignition Transformer if the Flame Probe does not establish the presence of the flame at the burner The operator is re
33. he control due to the rapid air change in the plenum from the fan The controls do not sense the instantaneous change in air temperature but take time to reach the plenum control setting before controlling the heater operation NOTE The firing rate must be set by the operator to make sure excessive temperature is not present in the plenum 33 34 Modulating Valve The Modulating Valve is a non electrical operating control The Modulating Valve is placed in the heater plumbing and controls the amount of fuel burned by the heater depending upon the temperature of the drying air If the temperature of the drying air is lower than the temperature setting of the Modulating Valve the Modulating Valve opens up and more fuel is burned to raise the drying air temperature If the drying air temperature is higher than the temperature setting the Modulating Valve restricts the amount of fuel to the heater The Modulating Valve has an interchangeable by pass orifice to maintain continuous low heat operation regardless of Modulating Valve setting The orifice is interchangeable for establishing lower or higher by pass flow through the Modulating Valve depending on conditions Heater Operational Adjustments Part Number 220491 Bulletin 464S 2 1 2002 Page 23 of 41 The following adjustments will have to be made depending upon the kind of heater and Plenum External controls being used These adjustments can not be made at the factory due to the dif
34. hrough the possible causes and remedies WARNING UNLESS OTHERWISE INDICATED CHECKS ARE MADE WITH THE POWER OFF USING VOLTMETER ON RESISTANCE SETTING Definition Continuity The ability to move electricity from one point to another a completed circuit The component checks that follow can be made on both the Downstream Centrifugal Heater or the Axial Heater except where defined for one model of heater only The order of checking components for each particular system is consistent with the sequence of the power being delivered to the components I SYMPTOM TURN POWER SWITCH ON NOTHING HAPPENS 1 Lack of power going to the unit CHECK MADE WITH POWER ON A Take a voltmeter or continuity tester put one lead to ground and the other on the top terminal of terminal block in fan control box Power lead is the black wire on top terminal on terminal block It should indicate 115 volts on the voltmeter or light should come on with continuity tester 2 Improper neutral A Check to be sure neutral wire is connected to the terminal block in the fan control box 1 Neutral needs to be provided from the disconnect to fan control box with the power supply 3 Check for power at toggle switch in heater Check made with POWER ON A Put one lead of voltmeter to toggle switch where power cord is connected and the other lead to ground If there is not any power check cord and fuse 4 Fuse may be blown A Visually check fuse 1 If
35. ldwell Kearney Nebraska Contact Caldwell if you have any problems or questions OUT OF WARRANTY SERVICE Products requiring Caldwell repair work will be repaired at the standard repair charge plus hourly charges after the first hour Field service work will require a field service charge plus travel expenses The repaired part will carry a 30 day limited warranty Your dealer will be responsible for warranty procedures in accordance with the Caldwell Service Policy See Dealer Policy Part Number 220491 Bulletin 464S 2 1 2002 Page 40 of 41 NOTES
36. ncurred in repairing or servicing any Caldwell products except as such repairs are made at Caldwell or by Caldwell Field Service Personnel or as approved in writing from Caldwell Customer Service IN WARRANTY REPLACEMENT The Caldwell Standard Limited Warranty Policy will cover any defective part of the product covered by the Standard Limited Warranty Equipment involved in a warranty claim under the above Standard Limited Warranty shall have the ORIGINAL WARRANTY REGISTRATIOIN CARD on file in Kearney Nebraska and have been properly installed maintained and operated according to the instructions provided by Caldwell WARRANTY CLAIM PROCEDURES When part failure occurs that in your judgment meets the conditions of the above Standard Limited Warranty contact your dealer to make arrangements for the shipment of a replacement item and the return of the defective equipment ELECTRIC MOTOR The Manufacturers of all electric motors used Caldwell carry a warranty for these items If the motor fails under the conditions of the Caldwell Standard Limited Warranty Policy and provided it was protected by the proper protective device the motor manufacturer s nearest authorized service center will repair it catalog for motor manufacturers service centers Any in warranty replacement motors not satisfactorily handled by motor manufacturer service centers and within the Standard Limited Warranty period and policy will be covered by Ca
37. ntrol box Spark Plug Wire The Spark Plug Wire is used to connect the spark plug to the ignition transformer Liquid Propane Hose 715276 The Liquid Propane Hose is used to connect the liquid plumbing line to the inlet of the vaporizer Vapor Propane Hose 155820 The Vapor Propane Hose is used to connect the vaporizer to the vapor propane line Burner High Limit Wire 701961 Wiring that connects the Burner High Limit and Burner Exhaust Limit to the control box Slave Relay 756692 A Slave Relay is utilized to prove that the Flame Probe is functioning properly with every trial for ignition If the Flame Probe is functioning properly the relay allows the purge to energize If the Flame Probe is not functioning properly the Slave Relay prevents the initiation of the ignition process Part Number 220491 Bulletin 464S 2 1 2002 Page 22 of 41 Optional External Plenum Control Not Shown 30 31 32 Humidistat Control 850982 The Humidistat Control is an electrical operating control that is wired into the heater to cycle the heater On and Off with respect to the relative humidity of the drying air The Humidistat Control is typically set at about 50 60 relative humidity of the drying When the relative humidity is higher than the humidistat setting the heater is cycled On and is left on until the relative humidity is below the humidistat setting If the relative humidity of the drying air is less than the humidi
38. obe Condition 33 Axial Heater Flame Probe Condition 34 LIST OF TABLES Downstream Heater Replacement Parts List For Common Parts 9 Downstream Heater Replacement Parts List For Specific Models 10 Axial Heater Replacement Parts List For Common Parts 17 Axial Heater Replacement Parts List For Specific Models 18 Part Number 220491 Bulletin 464S 2 1 2002 Page 3 of 41 CALDWELL HEATER SERVICE MANUAL THIS MANUAL IS FOR THE SERVICE AND MAINTENANCE OF HEATERS WITH SERIAL NUMBER OF 00A AND UP READ MANUAL THOROUGHLY BEFORE INSTALLING OR OPERATING YOUR CALDWELL HEATER KEEP THIS MANUAL IN A LOCATION FOR QUICK ACCESS AND REFERENCE SPECIAL SERVICE NOTICE If you are unable to remedy any service problem after thoroughly studying this manual contact the dealer from whom you purchased the unit YOUR DEALER IS YOUR FIRST LINE OF SERVICE GIVE HIM THE INFORMATION REQUESTED BELOW AND EXPLAIN YOUR PROBLEM If he is unable to correct the problem refer to the factory When calling the factory for service ask for the Customer Service Department Give the information requested below and explain your problem If adequate information relating to the problem is given the Service Department should be able to pin point the problem and suggest an immediate solu
39. ol to set the firing rate Orifice The Orifice is an opening at the end of the Heater Plumbing that develops a restriction to gas flow which allows the pressure gauge to develop a pressure reading so that the firing rate of the heater can be field set Liquid Shut Off Valve 714949 The Liquid Shut Off Valve is used as a manual shut off valve and is used to shut off the fuel to the heater The Liquid Shut Off Valve has only two positions open or closed The Liquid Shut Off Valve is only on LPGE Heaters 20 21 22 23 24 25 26 Part Number 220491 Bulletin 464S 2 1 2002 Page 13 of 41 Vapor Valve The Vapor Valve is used for preliminary adjustment of the firing rate by opening and closing the valve to generate the proper plenum temperature Once the proper firing rate is established the regulator needs to be adjusted to the firing rate required Vaporizer 752584 The Vaporizer is used on LPGE Heaters only and is used to convert the liquid propane gas to propane vapor gas by using the heat supplied by the burner Hydrostatic Pressure Relief Valve 716878 The Hydrostatic Pressure Relief Valve is used to protect the Heater Plumbing Components from excessive fuel pressure by relieving the excessive fuel pressure from gas trapped between shut off valves to the atmosphere If a hydrostatic pressure relief valve opens replace the relief valve Burner The Burner is the component in the heater where
40. place or adjust as needed See adjustment section Check all wire connections to be sure they are tight All external plenum controls nylon humidistat and thermostat combination should be inspected cleaned and checked every three days during operation Caldwell recommends that external plenum controls be removed and stored in a clean dry place when not in use Check adjustment of vaporizer twice daily or as changing weather conditions demand See heater adjustment section Part Number 220491 Bulletin 464S 2 1 2002 Page 28 of 41 IV Shut Down Procedures If heater is to be shut off for a prolonged period carry out the following steps 1 Close Fuel Valve at tank Allow the fuel to be burned out of the fuel line After the flame burns out close Vapor Valve and Liquid Valve Turn off heater placing Toggle Switch to Off position an PS Allow fan to run for two minutes in order to cool off heater Then shut fan off Shut off the power at the fan service disconnect 6 The Thermostat or Humidistat External Plenum Controls should be removed and stored in a clean dry place Part Number 220491 Bulletin 464S 2 1 2002 230V 3PHASE 460V 3PHASE Page 29 of 41 575V 3PHASE L J NOTE CIRCLED LETTERS AND NUMBERS REFER TO RELAY CONNECTIONS A FUSE 5 AMP AC B HEATER TOGGLE SWITCH AMB
41. quired to manually reset the Flame Sensing Relay before retrying for ignition Flame Probe 749812 The Flame Probe is a switch that is sensitive to heat and is used to establish the presence or absence of flame at the burner The Flame Probe is used with the Flame Sensing Relay as the Flame Safeguard Circuit of the heater The switch is opened on temperature rise Solenoid Valves Solenoid Valves are shut off valves that are electrically operated The valves are opened automatically when energized and are closed automatically when de energized Ignition Transformer 851790 The Ignition Transformer is a transformer used to create the 6000 secondary volts necessary for spark at the Spark Plug Spark Plug 851402 The Spark Plug is used to ignite the fuel at the burner The Spark Plug will spark while the Ignition Transformer is energized Fuel Line Strainer The Fuel Line Strainer is used to remove foreign particles from the fuel before the fuel enters the heater plumbing If these particles are not removed possible operating difficulties could occur Regulator The Regulator is used to regulate the amount of fuel Propane or natural gas going to the burner The Regulator is not used to requlate the fuel from the tank A separate Regulator should be used for regulating the fuel at the tank Pressure Gauge The Pressure Gauge is used to indicate the amount of fuel pressure at the Orifice The pressure is used as a to
42. s supply is not sufficient to maintain a flame in the heater unit even when the gas regulator is fully open Working from the top of the burner pipe place a quantity of 6 7 16 X 3 4 self tapping screws 960592 the burner pipe with the regulator in a fully open position If the flame is still not maintained repeat the process by continuing to add two more screws starting at the bottom of the burner pipe and again check the firing rate for the desired application Note Avoid plugging the burner pipe holes directly in front of the spark plug this will cause the burner to fail to ignite properly The flame probe may need to be repositioned lower on the burner so that it is in an area of higher flame intensity after the installation of the screws Note In both cases the number of screws placed in the burner pipe will vary Each individual case will be different for each customer to accomplish there given firing rate needed his her particular application Figure LOW Fire Part Number 220491 Bulletin 464S 2 1 2002 Page 27 of 41 HEATER MAINTENANCE The following procedures should be followed and maintenance performed before starting the unit at the beginning of every season and also during operation 1 The fuel line strainers should be taken out and cleaned plugged screen will restrict the gas flow to the unit
43. stat setting the heater is cycled Off until such time that the relative humidity would become greater than the setting of the humidistat The Humidistat Control is for low temperature drying Thermostat Control 851014 The Thermostat Control is an electrical operating control that is wired into the heater to cycle the heater On and Off with respect to the temperature of the drying air The thermostat is set at a desired temperature and if the temperature is higher than the thermostat setting the heater is cycled Off If the drying air temperature is less than the thermostat setting the heater is cycled On and is left on until such time that the drying air temperature is above the thermostat setting Humidistat Thermostat Control 870974 The Humidistat Thermostat Control is an electrical operating control that is wired into the heater to cycle the heater On and Off with respect to both the drying air relative humidity and temperature The Humidistat Thermostat Control will cycle the heater on if either the drying air relative humidity is too high or the drying air temperature is too low with respect to the humidity setting or temperature setting of the control NOTE The optional external plenum controls 30 32 do not function in the same manner as a thermostat in a house When the bin plenum controls reach the set point the heater is then shut off In the off mode the bin s plenum temperature will drop below the set point of t
44. ting Valve operating condition by turning the Modulating Valve handle in two revolutions adjusting the regulator to the desired pressure and then resetting the Modulating Valve to the desired plenum temperature Part Number 220491 Bulletin 464S 2 1 2002 Page 26 of 41 Down Stream Heater Low Fire Adjustments Low Fire Natural Gas Applications Installation 1 Low Fire Application Low Temperature Rise This application is to acquire a low temperature rise above ambient temperature In order to accomplish this some of the holes in the burner pipe may need to be plugged to allow a lower firing rating Working from the top of the burner pipe place a quantity of 6 7 16 X 7 4 self tapping screws 960592 in the burner pipe and try adjusting the regulator pressure to get the temperature rise desired If the temperature rise is still higher than desired and flame can not be maintained at a lower regulator pressure setting continue to add two more screws starting at the bottom of the burner pipe and again check the firing rate for the desired application Note Avoid plugging the burner pipe holes directly in front of the spark plug this will cause the burner to fail to ignite properly The flame probe may need to be repositioned lower on the burner so that it is in an area of higher flame intensity after the installation of the screws 2 Natural Gas Applications Low Inlet Gas Pressure This application is when the ga
45. tion CHIEF INDUSTRIES AGRI INDUSTRIAL DIVISION SERVICE POLICY IS INCLUDED AT THE END OF THE MANUAL 1 Heater Model Number 2 Heater Serial Number 3 Fan Model Number 4 Fan Serial Number MODEL SERIAL NO PART NO 5 of Fuel 6 of External Plenum Control Used 7 Setting of External Plenum Control 8 Approximate Operating Pressure 9 Hours Unit has been in Operation 10 Size of Bin Diameter 11 Height 12 Grain Depth 11 Kind of Grain 12 Moisture Content ______U_UOU____ Figure 1 Typical Serial Number Plate 12 Dealer Purchased From 13 Date Purchased THE ABOVE INFORMATION MUST BE AVAILABLE BEFORE CONTACTING THE DEALER OR FACTORY FOR SERVICE ASTERISKED ITEMS SHOULD BE FILLED IN AT DATE OF PURCHASE MODEL NUMBER DESCRIPTION Part Number 220491 Bulletin 464S 2 1 2002 Page 4 of 41 The heater model nomenclature distinguishes the application of the heater The information includes a designation of the applicable fan and type of fuel to be utilized either natural gas vapor propane or liquid propane The model number is stamped on the serial number plate and the definition of the model number nomenclature is as follows Downstream Heater Example 1015 T LPGEM b a Heater Unit Canadian 6 1015 Fan Model Required by Horsepower Where 1015 C27 10 or C27 15 2025 C30 20 or C30 25
46. ture limiting control used to protect the heater not the bin plenum from too high of a temperature The Burner Exhaust Limit is set to shut off the heater if the temperature at the sensor exceeds 270 F 132 C The control will automatically allow the heater to re ignite after the heater cools Burner High Limit 712299 The Burner High Limit Control located just behind the burner is a manual resetting temperature limiting control used to protect the heater not the bin plenum from flame generated behind the burner The Burner High Limit Control is set to shut off the heater if the heater temperature reaches 160 F 71 C To restart the heater the operator must manually reset the Burner High Limit Control by pushing the button on top of the heater Air Switch 785691 The Air Switch is a control that senses the flow of air from the fan to the heater If for any reason the air flow is stopped the Air Switch will shut off the heater The Air Switch will keep the heater shut off until air flow from the fan is re established If the Air Switch cycles off from a lack of air turn the heater toggle switch off before restarting the fan Vapor Temperature Limit LPGE Units Only 157200 The Vapor Temperature Limit is an automatic resetting temperature limiting control used to protect the Solenoid Valve and Regulator from being damaged due to excessive gas temperature coming from the vaporizer Also the Vapor Temperature Limit protects the
47. uge to develop a pressure reading so that the firing rate of the heater can be field set 20 21 22 23 24 25 26 27 28 29 Part Number 220491 Bulletin 464S 2 1 2002 Page 21 of 41 Liquid Shut Off Valve 714949 The Liquid Shut Off Valve is used as a manual shut off valve and is used to shut off the fuel to the heater The Liquid Shut Off Valve has only two positions Open or Closed The Liquid Shut Off Valve is only on LPGE Heaters Vaporizer 702035 The Vaporizer is used on LPGE Heaters only and is used to convert the liquid propane gas to propane vapor gas by using the heat supplied by the burner Hydrostatic Pressure Relief Valve 716878 The Hydrostatic Pressure Relief Valve is used to protect the Heater Plumbing Components from excessive fuel pressure by relieving the excessive fuel pressure from gas trapped between shut off valves to the atmosphere If a hydrostatic pressure relief valve opens replace the relief valve Ring Burner The Ring Burner is a ring shaped component in the heater where the fuel and air are mixed and then burned Terminal Block 749614 The Terminal Block is used as a junction block for connecting the lead wires of the various electrical parts Toggle Switch Boot 712034 The Toggle Switch Boot is used to eliminate water entering the heater controls through the Toggle Switch Flame Probe Wire The Flame Probe Wire is used to connect the flame probe to the co
48. ut of the flame See adjustment section Vil SYMPTOM NOT ENOUGH HEAT 1 Orifice is too small or dirty A Check service manual of the heater for the proper size orifice for your unit and application Use the Firing Rate Table guide for setting the firing rate B Remove orifice and check for obstructions and then reinstall orifice 2 Insufficient gas pressure A Make sure proper gas line size is installed to the heater 3 Vaporizer not hot enough A Vapor plumbing line on unit will be cold to touch 1 Refer to the adjustment section to adjust vaporizer to be in greater contact to the flame VII SYMPTOM EXTERNAL PLENUM CONTROL NOT FUNCTIONING 1 Check wiring schematic and be sure the control is wired into the heater properly Make visual check of the external plenum control cord to be sure it isn t cut or shorted Check the external plenum control setting Adjust external plenum control for desired setting Refer to adjustment section Part Number 220491 Bulletin 464S 2 1 2002 Page 39 of 41 PRODUCT SERVICE Our top priority is to assure customer satisfaction on Caldwell products If a dealer requires assistance from Caldwell contact our Service Department The dealer purchasing a product from Caldwell will be responsible for the installation operation and service in accordance with Caldwell Service Policy The dealer will also be responsible for all Standard Limited Warranty procedures in accordance with
49. valves that are electrically operated The valves are opened automatically when energized and are closed automatically when de energized Ignition Transformer 851790 The Ignition Transformer is a transformer used to create the 6000 secondary volts necessary for spark at the Spark Plug Spark Plug 851402 The Spark Plug is used to ignite the fuel at the burner The Spark Plug will spark while the Ignition Transformer is energized Fuel Line Strainer The Fuel Line Strainer is used to remove foreign particles from the fuel before the fuel enters the heater plumbing If these particles are not removed possible operating difficulties could occur Vapor Valve The Vapor Valve is used for preliminary adjustment of the firing rate by opening and closing the valve to generate the proper plenum temperature Once the proper firing rate is established the regulator needs to be adjusted to the firing rate required Regulator The Regulator is used to regulate the firing rate of the heater The Regulator is not used to regulate the fuel from the fuel sources A separate Regulator should be used for regulating the fuel at the fuel source Pressure Gauge The Pressure Gauge is used to indicate the amount of fuel pressure at the Orifice The pressure is used as a tool to set the firing rate Orifice The Orifice is an opening at the end of the Heater Plumbing that develops a restriction to gas flow which allows the pressure ga
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