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PNEG-1086
User Manual
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GSI PNEG-1086 User Manual

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PNEG-1086
42'-60' Externally Stiffened 2 Ring Door
Assembly Instructions
PNEG-1086
Date: 06-15-12
Table of Contents

Contents

Chapter 1 Introduction ..........................................................................................................................................4
Chapter 2 Safety .....................................................................................................................................................5
Safety Guidelines .................................................................................................................................. 5
General Safety Statement ..................................................................................................................... 6
Safety Instructions ..................... ... .... .......................................... ... ... ..................................................... 7
Safety Sign-Off Sheet ........................................................................................................................... 9
Proper Storage of Grain Bin/Silo Materials Prior to Construction ....................................................... 10
Chapter 3 Safety Decals ......................................................................................................................................11
Roof Damage Warning and Disclaimer ............................................................................................... 11
Chapter 4 Important Note ....................................................................................................................................14
Chapter 5 Assembly Instructions ......................... .................................................... ..........................................15
Chapter 6 Assembly Drawings ...........................................................................................................................17
Chapter 7 Warranty ..............................................................................................................................................29
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 3

1. Introduction

READ THIS MANUAL carefully to learn how to properly use and install equipment. Failure to do so could result in personal injury or equipment damage.
INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all quantities are correct. The customer should report and note any damage or shortage on the bill of lading to justify their claim to the transport company.
THIS MANUAL SHOULD BE CONSIDERED a permanent part of your equipment and should be easily accessible when needed.
This warranty provides you the assurance that the company will back its products when defects appear within the warranty period. In some circumstances, the company also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the factory specifications, the warranty will become void and field improvements may be denied.

2. Safety

DANGER
WARNING
CAUTION
NOTICE
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Safety Guidelines
This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections. Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death.
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 5
2. Safety
This product has sharp edges, which may cause serious injury. To avoid injury, handle sharp edges with caution and always use proper protective clothing and equipment.
General Safety Statement
Our foremost concern is your safety and the safety of others associated with grain handling equipment. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel.
As owner and/or operator, you are responsible to know what requirements, hazards, and precau tions exist and inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel. Avoid any alterations to the equipment, which may produce a very dangerous situation, where SERIOUS INJURY or DEATH may occur.
You should consider the location of the bin site relative to power line locations or electrical transmission equipment. Contact your local power company to review your installation plan or for information concerning required equipment clearance. Clearance of portable equipment that may be taken to the bin site should also be reviewed and considered. Any electrical control equipment in contact with the bin should be properly grounded and installed in accordance with National Electric Code provisions and other local or national codes.
This product is intended for the use of grain storage only. Any other use is a misuse of the product.
Sidewall bundles or sheets must be stored in a safe manner. The safest method of storing sidewall bundles is laying horizontally with the arch of the sheet upward, like a dome. Sidewall sheets stored on edge must be secured so that they cannot fall over and cause injury. Use care when handling and moving sidewall bundles.
Personnel operating or working around equipment should read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment.
2. Safety
Follow Safety Instructions
Carefully read all safety messages in this manual and safety signs on your machine. Keep signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from the manufacturer.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machinery in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.
If you do not understand any part of this manual or need assistance, contact your dealer.
Read and Understand Manual
Practice Safe Maintenance
Understand service procedures before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is in operation. Keep hands, feet, and clothing away from rotating parts.
Keep all parts in good condition and properly installed. Fix damage immediately . Replace worn or broken p arts. Remove any built-up grease, oil, and debris.
Maintain Equipment and Work Area
Safety Instructions
Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel.
As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions exist, and to inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel. Avoid any alterations to the equipment. Such alterations may produce a very dangerous situation where SERIOUS INJURY or DEATH may occur.
This equipment shall be installed in accordance with the current installation codes and applicable regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 7
2. Safety
Prepare for Emergencies
Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
Keep Emergency Equipment Quickly Accessible
Wear Protective Clothing
Wear close-fitting clothing and safety equipment appropriate to the job.
Remove all jewelry.
Tie long hair up and back.
Wear safety glasses at all times to protect eyes from debris.
Wear gloves to protect your hands from sharp edges on plastic or steel parts.
Wear steel-toed boots to help protect your feet from falling debris. Tuck in any loose or dangling shoestrings.
A respirator may be needed to prevent breathing potentially toxic fumes and dust.
Wear a hard hat to help protect your head.
Wear appropriate fall protection equipment when working at elevations greater than six feet (6').
Eye Protection
Gloves
Steel-Toed Boots
Respirator
Hard Hat
Fall Protection
2. Safety
Safety Sign-Off Sheet
As a requirement of O.S.H.A., it is necessary for the employer to train the employee in the safe operating and safety procedures for this equipment. This sign-off sheet is provided for your convenience and personal record keeping. All unqualified persons are to stay out of the work area at all times. It is strongly recommended that another qualified person who knows the shut down procedure be in the area in the event of an emergency.
Date Employee Name Supervisor Name
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 9
2. Safety
Proper Storage of Grain Bin/Silo Materials Prior to Construction
Wet storage stain (rust) will develop when closely packed bundles of galvanized material, such as sidewall and roof sheets, have moisture present. Inspect roof and sidewall bundles on arrival for any moisture. If moisture is present, it must not be allowed to remain between the she ets. Separate the sheets or panels immediately and wipe them down. Spray with a light oil or diesel fuel.
If possible, sidewall bundles, roof sheets and other closely packed galvanized materials should be stored in a dry, climate controlled building. If outdoor storage is unavoidable, the materials should be stored so that they are raised above the ground and vegetation. Any stacking an d spacing mat erials sho uld not be corrosive or wet. Be sure to protect materials from the weather, but permit air movement around the bundles if possible.
Storing roof bundles and sidewall sheets at a slight incline can also help minimize the presence of moisture. Storing the bundles with the center of the dome up (like an arch) is one option for minimizing moisture during storage. Sidewall bundles can also be stored on edge but must be secured so that they do not fall over and cause injury.
If “white rust” or “wet storage stain” occurs, contact the manufacturer imme diately about ways to minimize the adverse effect upon the galvanized coating.

3. Safety Decals

Excessive vacuum (or pressure) may damage roof. Use positive aeration system. Make sure all roof vents are open and unobstructed. Start roof fans when supply fans are started. Do not operate when conditions exist that may cause roof vent icing.
DC-969
CAUTION!
The manufacturer does not warrant any roof damage caused by excess ive v acuum or internal pressure from fans or other air moving systems. Adequate ventilation and/or “makeup air” devices should be provided for all powered air handling systems. The manufacturer does not recommend the use of downward flow systems (suction). Severe roof damage can result from any blockage of air passages. Running fans durin g high humidity/cold weather conditions can cause air exhaust or intake ports to freeze.
Roof Damage Warning and Disclaimer
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 11
3. Safety Decals
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
Keep clear of all augers. DO NOT ENTER this bin!
Failure to heed these
warnings will result in
serious injury or death.
If you must enter the bin:
1. Shut off and lock out all power.
2. Use a safety harness and safety line.
3. Station another person outside the bin.
4. Avoid the center of the bin.
5. Wear proper breathing equipment or respirator.
DC-GBC-1A
ATTENTION: The decal shown below should be present on the outside of the door cover of the 2 ring, 24" porthole door cover and the roof manway cover. If a decal has been damaged or is missing in any of these locations, contact the manufacturer for a free replacement decal.
GSI Decals
1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421
3. Safety Decals
Failure to heed these warnings
could result in serious injury, death,
structural damage or collapse of tank.
1. Use CENTER FLOOR OUTLET ONLY until NO grain remains above this outlet.
2. Side floor outlets to be used ONLY when above condition is satisfied.
3. Lock all side floor outlets to avoid accidental premature use.
4. See manufacturers instructions for proper use of factory supplied sidedraw (wall) discharge systems.
UNLOADING INSTRUCTIONS:
DC-GBC-2A
WARNING
DON’T
DO
ATTENTION: The decal shown below should be present on the outside of the door cover of the 2 ring, 24" porthole door cover and the roof manway cover. If a decal has been damaged or is missing in any of these locations, contact the manufacturer for a free replacement decal.
GSI Decals
1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 13

4. Important Note

This GSI commercial 2 ring door is designed for use in the 2.66" corrugation NCL series of tanks manufactured after 1991 utilizing the “universal” or hat shaped stiffener. This door is intended for use with a tank specifically structured for the installation of the 2 ring door. Special sidewall sheets are provided as part the tank sidewall bundles. You must consult with GSI concerning retrofitting into any existing GSI manufactured tank.
The door package NCWT0108 is designed for use in 42'-60' (12.81 m-18.29 m) diameter tanks with a maximum eave height = 90'-10"/27.69 meters and external stiffeners.
You should not attempt to install this door in any 2.66" corrugation GSI “Z” stiffener tank (pre 1991 series). This door should not be installed in any GSI 4.00" corrugation series tank. Consult with GSI concerning retrofitting into any existing GSI manufactured tank to determine compatibility
of the door package with the existing sidewall and stiffener configuration.
This door should not be installed in any tank not manufactured by GSI.

5. Assembly Instructions

Written instructions for installation of a NCWT0108 (42'-60' diameter bin/silo) 2 ring door package in a externally stiffened tank.
1. The commercial 2 ring door is installed in the bottom 2 rings.
2. The door should normally be placed in line with the conveyor. A intermediate discha rge well should be located near the wall to clear grain from the area of the access door (as with any access door). The door must be positioned directly below the vertical seam as shown in Figure 6A on Page 17.
3. The door has an inside frame weldment and an external frame weldment/assembly. If the tank has not been erected the internal frame weldment should be placed inside the tank before erection. If the tank has been erected or erection has begun, it will be necessary to remove sidewall and stiffeners in the door placement area to place the inside frame weldment.
The external door frame stiffener will mount at the standard externally stiffened tank anchor bolt location. (See Page 24.) If bolts have been pre-placed then place the frame and stiffeners over the pre-placed bolts. If drill in anchors are to be used it is recommended the holes be pre-drilled at the proper location.
4. The stiffeners are mounted in the frame directly under the tank stiffener columns. (See Page 25.) For the case of the externally stiffened tank these stiffeners will be mounted in the external frame. The frame should have the stiffeners already in place with two (2) bolts to hold them in location. These bolts will need to be removed to install the door, however the stiffeners may be left in position in the frame. The stiffeners will mount in the frame such that t he tank stiffener will bear directly above it. Should the stiffeners not be so placed, they should be placed in that location. Standard base stiffener weldments mount above the frame stiffeners.
5. Left and right hand jamb plates (NCWT0091L and NCWT0091R) are provided for attachment of the sidewall sheets to the door frame. The jamb plate will mount between the internal an d external frame. Place the jamb plate between the internal and external frame and bolt the frame, plate and stiffener together utilizing 7/16" diameter bolts. Utilize 7/16" x 1-1/2" bolts (S-3885) for the plate to jamb connection utilize 7/16" x 2" bolt for stiffener to jamb to plate connection. (See Page 26.) At the jamb plate to frame connection install the bolts with the head and sealing washer on the outside of the tank. At the stiffener to frame to plate connection install the bolts with the head and sealing wa sher on the inside of the tank.
The internal door panel hinges will mount utilizing stiffener to frame bolts (on the inside of the tank). Place an additional sealing washer under the hinge at those bolt locations before bolting it in place. Shim as necessary with 7/16" flat washers to obtain proper alignment with door panel hinges.
(See Page 27.)
6. The sidewall sheets to the left and right of the door will mount to the outside of the jamb plate. Two (2) special short sidewall sheets (44") and two (2) standard length (119"), special punched sheets are provided. Attach the sidewall to the jamb plate utilizing 3/8" diameter x 1-1/2" long bolts.
(See Page 26.) Corrugated sealing strip, CWT-0053 is provided. This may be mounted at the o uter
edge and inner edge of the jamb plate to sidewall interface. Caulk around the seal strip as well. A flat washer may be required under the nut for certain gauge thickness.
Bolt head/sealing washer should be on the outside of the tanks for this connection.
NOTE: For tanks that utilize 13 gauge or thinner material 3/8" x 1" bolts may be used to attach the
sidewall to the jamb plate.
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 15
5. Assembly Instructions
Written instructions for installation of a NCWT0108 (42'-60' diameter bin/silo) 2 ring door pa ckage in a externally stiffened tank. (Continued)
The horizontal seam of the sidewall sheet above the door header will bolt to the jamb plate where it extends above the door frame. The sidewall will be on the exterior of the plate. Install base angle (B-6753) at the area the plate does not extend above. Utilize silicon caulk as necessary to seal this location.
Standard base stiffeners will mount directly above the frame stiffener. Shim as necessary for firm support and bolt the stiffeners together using a 3/4" x 5" bolt, 3/4" nut and 3/4" washer.
7. Bearing pins, WD-6224 (8), are mounted to the inside frame flange at the eight (8) large/0.65" x 0.75" slots. Use S-2741, 5/16" x 1-1/2" bolts and attach the bearing pins at these eight (8) locations by inserting the grooved pin into the hole and running the 5/16" bolt to the inside. (See Page 21.) Use 5/16" washer (S-845) and 5/16" flange head nut (S-3611) to secure bearing pin.
8. Assemble the door handle reinforcement angles, door handles, latches and hinges to the top and bottom inner door panels as shown in Pages 19 and 20. Install the 1/2" x 1-1/2" bolts in the outer door frame at four (4) locations and thread the door latch bar holder (WD-6234) onto the bolt. The door handle will mount over these holders when installed. Utilize washers if necessary to adjust the latch bar holder position. (See Page 21.) Mount the door panel onto the four (4) bearing pins and lock the latches over the latch bar holder. Center the bearing pins in the door panel holes and tighten. Then, attach the door panel hinges to the frame hinges. Be sure door panels open smoo thly and the latch bars lock completely. Apply 1/2" x 1" seal strip to the inner frame weldment to seal around the inner panels.
9. Bolt the outer cover attachment angles onto the outer frame weldment with 5/16" x 1-1/4" bolts. Use a 5/16" flat washer on all slotted connections. Refer to Page 18 for details.
10. Attach the outer cover hinge weldment (NCWT0165) and the latch brackets (NCWT0166) to the outer cover angles with 5/16" x 1-1/4" bolts. Bolt head should be on the inside for all outer cover angle connections. Use a 5/16" flat washer on all slotted connections. Refer to Page 18 for details.
11. Assemble the exterior cover as shown in hinges (NCWT0170) and reinforcement channels to the outer cover as shown. Use 5/16" x 3/4" bolts for all outer cover reinforcement channel connections only. Use 5/16" x 1-1/4" bolts for all retaining bracket and hinge connections. The bolt head with sealing washer should be on the outside of the door cover for these connections. Attach the outer cover assembly to the outer cover hinge weldments with 3/8" x 4-1/2" bolts and nuts. Adjust hinges until outer cover opens and closes smoothly. Apply 1/2" x 1" foam seal strip to the outer frame weldment to seal outer cover. Fill all un-used bolt holes with 3/8" x 1" bin bolts. Check to ensure that the unloading decals (DC-GBC-2A and DC-GBC-2S) are installed on the outside of the outer door cover. Check to ensure tha t the danger decals (DC-GBC-1A and DC-GBC-1S) are installed on the inside of the outer door cover. Please contact GSI immediately if decals are missing or damaged.
12. Caulk as necessary at the top and bottom juncture of the door frame and the sidewall and foundation.
Page 27
. Install the retaining brackets (WD-033), outer cover

6. Assembly Drawings

Figure 6A
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 17
6. Assembly Drawings
Figure 6B
6. Assembly Drawings
Figure 6C
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 19
6. Assembly Drawings
Figure 6D
6. Assembly Drawings
WD-6224 Four (4) per door panel attach
bearing pins loosely in the door frame.
Install door panels in proper position, then
center bearing pins in door panel hole and
tighten. Refer to assembly instructions
Step 7 on Page 16.
WD-6234 Four (4) per door panel.
Refer to assembly instructions Step 8
on Page 16 for order of assembly.
Figure 6E
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 21
6. Assembly Drawings
Figure 6F
6. Assembly Drawings
Figure 6G
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 23
6. Assembly Drawings
Figure 6H
6. Assembly Drawings
Ref # Part # Description
1 NCWT0094 Outer Frame Weldment
2 NCWT0096 Inner Frame Weldment
3 NCWT0097 Stiffener Weldment
4 Special Long Sidewall
5 Special Short Sidewall
6 Standard Base Stiffener
7 NCWT0091L Left Jamb/Sidewall Plate
8 NCWT0091R Right Jamb/Sidewall Plate
See Page 26 for hardware specifications.
Figure 6I
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 25
6. Assembly Drawings
NOTE: Refer to assembly instructions Steps 5
and 6 on Page 15 for assembly and bolt usage.
Figure 6J
6. Assembly Drawings
Figure 6K
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 27
NOTES

7. Warranty

9101239_1_CR_rev7.DOC (revised July 2009)
GSI Group, LLC Limited Warranty
The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier. The end-user’s sole remedy (and GSI’s only obligation) is to repair or replace, at GSI’s option and expense, products that in GSI’s judgment, contain a material defect in materials or workmanship. Expenses incurred by or on behalf of the end-user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the end-user.
Warranty Extensions:
The Limited Warranty period is extended for the following products:
Product Warranty Period
Performer Series Direct Drive Fan Motor 3 Years
AP Fans and Flooring
Cumberland Feeding/Watering Systems
Grain Systems Grain Bin Structural Design 5 Years Grain Systems
Farm Fans Zimmerman
All Fiberglass Housings Lifetime All Fiberglass Propellers Lifetime Feeder System Pan Assemblies 5 Years ** Feed Tubes (1-3/4" and 2.00") 10 Years * Centerless Augers 10 Years * Watering Nipples 10 Years *
Portable and Tower Dryers 2 Years Portable and Tower Dryer Frames and
Internal Infrastructure †
5 Years
* Warranty prorated from list price: 0 to 3 years - no cost to end-user 3 to 5 years - end-user pays 25% 5 to 7 years - end-user pays 50% 7 to 10 years - end-user pays 75% ** Warranty prorated from list price: 0 to 3 years - no cost to end-user 3 to 5 years - end-user pays 50%
† Motors, burner components
and moving parts not included. Portable dryer screens included. Tower dryer screens not included.
GSI further warrants that the portable and tower dryer frame and basket, excluding all auger and auger drive components, shall be free from defects in materials for a period of time beginning on the twelfth (12 and continuing until the sixtieth (60
th
) month from the date of purchase (extended warranty period). During the extended
th
) month from the date of purchase
warranty period, GSI will replace the frame or basket components that prove to be defective under normal conditions of use without charge, excluding the labor, transportation, and/or shipping costs incurred in the performance of this extended warranty.
Conditions and Limitations:
THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH ABOVE. SPECIFICALLY, GSI MAKES NO FURTHER WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH: (I) PRODUCT MANUFACTURED OR SOLD BY GSI OR (II) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT, REPRESENTA TIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCTS.
GSI shall not be liable for any direct, indirect, incidental or consequential damages, including, without limitation, loss of anticipated profits or benefits. The sole and exclusive remedy is set forth in the Limited Warranty, which shall not exceed the amount paid for the product purchased. This warranty is not transferable and applies only to the original end-user. GSI shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent or distributor.
GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which it manufactured. Modifications to products not specifically delineated in the manual accompanying the equipment at initial sale will void the Limited Warranty.
This Limited Warranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration, accident or which have been improperly/inadequately maintained. This Limited Warranty extends solely to products manufactured by GSI.
Prior to installation, the end-user has the responsibility to comply with federal, state and local codes which apply to the location and installation of products manufactured or sold by GSI.
PNEG-1086 42'-60' Externally Stiffened 2 Ring Door 29
This equipment shall be installed in accordance with
the current installation codes and applicable
regulations, which should be carefully followed in all
cases. Authorities having jurisdiction should be
consulted before installations are made.
Copyright © 2012 by GSI Group Printed in the USA
GSI Group
1004 E. Illinois St.
Assumption, IL 62510-0020
Phone: 1-217-226-4421
Fax: 1-217-226-4420
www.gsiag.com
CN-205772
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