GSI PNEG-1314 User Manual
2003 Top Dry Service School
GSI / Top Dry
Service School
2003
PNEG-1314
1
2003 Top Dry Service School
Contents
Safety Pages..........................4
Product Updates...................7
Softwar e Revisions..............1 1
Batch T roubleshooting.......19
Autoflow T roubleshooting..25
Diagnostics..........................32
Warranty.............................40
2
2003 Top Dry Service School
3
2003 Top Dry Service School
Roof Damage Warning and Disclaimer
GSI DOES NOT WARRANT ANY ROOF DAMAGE
CAUSED BY EXCESSIVE VACUUM OR INTERNAL
PRESSURE FROM F ANS OR OTHER AIR MOVING
SYSTEMS. ADEQUATE VENTILATION AND/OR
"MAKEUP AIR" DEVICES SHOULD BE PROVIDED
FOR ALL POWERED AIR HANDLING SYSTEMS.
GSI DOES NOT RECOMMEND THE USE OF DOWNWARD FLOW SYSTEMS (SUCTION). SEVERE
ROOF DAMAGE CAN RESULT FROM ANY
BLOCKAGE OF AIR PASSAGES. RUNNING F ANS
DURING HIGH HUMIDITY/COLD WEA THER CONDITIONS CAN CAUSE AIR EXHAUST OR INT AKE
PORTS TO FREEZE.
Operating Instructions
The principal concern of the GSI Group, Inc. ("GSI")
is your safety and the safety of others associated
with grain handling equipment. This manual is written to help you understand safe operating procedures, and some of the problems that may be encountered by the operator or other personnel.
The symbol shown is used to call your
attention to instructions concerning your
personal safety. Watch for this symbol; it points out important safety precautions. It means "ATTENTION",
"WARNING", "CAUTION", and
"DANGER". Read the message and
be cautious to the possibility of personal injury or death.
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 who are in the fan area.
A void any alterations to the equipment. Such alterations may produce a very dangerous situation,
where serious injury or death may occur.
Safety Alert Symbol
WARNING! BE ALERT!
Personnel operating or working
around electric fans should read this
manual. This manual must be
delivered with the equipment to its
owner. Failure to read this manual
and its safety instructions is a misuse
of the equipment.
4
2003 Top Dry Service School
Grain Systems, Inc.
recommends contacting your
local power company , and
having a representative
survey your installation so
the wiring is compatible with
their system, and adequate
power is supplied to your
unit.
Safety decals should be read
and understood by all people in the
grain handling area. The rotating
blade, fire warning decals and
voltage danger decal must be displayed on the fan can. The bottom right decal should be present
on the inside bin door cover of the
two ring door, 24" porthole door
cover and the roof manway cover.
If a decal is damaged or is
missing contact:
Grain Systems, Inc.
1004 E. Illinois St.
Assumption, IL 62510
217-226-4421
A free replacement will be sent to
you.
5
2003 Top Dry Service School
READ THESE INSTRUCTIONS
BEFORE OPERA TION AND SER VICE
SAVE FOR FUTURE REFERENCE
1. Read and understand the operating manual before trying to operate the
dryer.
2. Power supply should be OFF for service of electrical components. Use
CAUTION in checking voltage or other procedures requiring power to
be ON.
3. Check for gas leaks at all gas pipe connections. If any leaks are detected, do not operate the dryer. Shut down and repair before further
operation.
4. Never attempt to operate the dryer by jumping or otherwise bypassing
any safety devices on the unit.
5. Set pressure regulator to avoid excessive gas pressure applied to burner
during ignition and when burner is in operation. Do not exceed maxi-
mum recommended drying temperature.
6. Keep the dryer clean. Do not allow fine material to accumulate in the
plenum or drying chamber.
Use Caution in the
Operation of this
Equipment
The design and manufacture of this
dryer is directed toward operator
safety. However, the very nature
of a grain dryer having a gas burner,
high voltage electrical equipment and
high speed rotating parts, does
present a hazard to personnel, which
can not be completely safeguarded
against, without interfering with efficient operation and reasonable access to components.
Use extreme caution in working
around high speed fans, gas-fired
heaters, augers and auxiliary conveyors, which may start without warning when the dryer is operating on
automatic control.
7. Use CAUTION in working around high speed fans, gas burners, augers
and auxiliary conveyors which START AUTOMATICALLY.
8. Do not operate in any area where combustible material will be drawn into
the fan.
9. Before attempting to remove and reinstall any propellor, make certain to
read the recommended procedure listed within the servicing section of
the manual.
10. Clean grain is easier to dry . Fine material increases resistance to airflow
and requires removal of extra moisture.
This product is intended for the use of grain handling only. Any other
use is considered a misuse of the product.
Some edges of the product components can be sharp. It is recommended that each component of this product be examined to determine if there are any safety considerations to be taken. Any and all
necessary personal protective equipment should be worn at all tines
when handling, assembling, installing and operation of the product
and/or components.
Guards are removed for illustration purpose only. All guardsmust be
KEEP THE DRYER CLEAN
DO NOT ALLOW FINE
MATERIAL TO ACCUMULATE
IN THE PLENUM CHAMBER
OR SURROUNDING THE OUT-
SIDE OF THE DRYER
Continued safe, dependable operation of automatic equipment depends, to a great degree, upon the
owner. For a safe and dependable
drying system, follow the recommendations within this manual, and make
it a practice to regularly inspect the
operation of the unit for any developing problems or unsafe conditions.
Take special note of the safety precautions listed above before attempting to operate the dryer.
6
2003 Top Dry Service School
GSI / Top Dry
Product Updates
* Adjustable Drying Chamber High Level Rotary Switch
* Plenum Hi-Limit
* Software Updates
7
DR YING CHAMBER HILIMIT ROTARY
SWITCH INSTALLATION
Assemble 1/4” shaft to rotary switch with 1/4”
coupler and rolled pins. Next Screw 1-1/4” pipe
coupler to bottom of rotary switch. Insert 1-1/4”
pip through adjustable roof mount weldment.
Leave 1-1/4” pipe sticking out the top of the
weldment 3” as shown in Diagram. Install paddle
to 1/4” shaft assembly with coupler and rolled pins.
Switch assembly is now ready to mount to roof.
2003 Top Dry Service School
3.00”
COMPRESSION COUPLER
ROOF MOUNT PLATE
8
2003 Top Dry Service School
TOP DRY PLENUM HI LIMIT INSTALLATION
1. Assemble two pieces of conduit together with coupler.
2. Mount conduit clamps to conduit assembly.
3. Locate conduit assembly on the bottom of a rafter at least 2 feet to one side of the fan
entrance. Do not install between two f an entr ance s.
4. Mark bin wall where conduit will pass through and drill a hole just large enough to allow the
conduit to pass through. Seal this with caulking when complete.
5. Install white PVC box assembly on outside of bin wall.
6. Insert 10’ capillary into condu it assembly.
7. Connect SJO cord to hi limit and connect wires to terminals 20 and 21 on the master fan
terminal strip. These terminals are J7-08, and J7-03.
9
2003 Top Dry Service School
10
2003 Top Dry Service School
GSI / Top Dry
Software Revisions
11
2003 Top Dry Service School
N
p
p
N
Network Autoflow Display Board Software Revisions
*********************************************************************
VERSION: 2.15 REVISED BY: Steve Logue RELEASE DATE: Oct 17, 2002
OTE: This Version does NOT support Wat chdog and the Heater Version MUST be 1.09. HEATER VERS – 1.09 IO
VERS – 1.07
1) The "FAN DELAY" is now called "MOTOR DELAY".
2) Added a way for GSI to reset total hours.
3) Here is a list of switches/features which can be found under the setup screens accessed via holding in on MODIFY whil e
owering on the Control Power.
Below is a description for each defin in g w hat it means t o disable/enable them :
i)
AIRSWITCH
requirements for the burner
regardless of the actual air switch state.
ii)
LOW LE VEL SWITCH
state of the rotary swi tc h.
When disabl ed the dryer will think the l ow level switch is always covered.
iii)
WET TANK SWITCH
always covered w it h grain.
iv)
START FANS WITH
Disabled means dryer will
start according to drying chamber low level switch.
v)
AERATION FAN BYPASS
dryer shutdow n.
4) The REFILL TIM ER and the TIME UNTIL LOAD OFF screens are only shown w hen t he dr yer is set for Autobat c h mode.
5) There are two more settings available under the "Power on and Modify key in" se quence for the user to set how many de gr ees a
measured temperature can
exceed a set poi nt w ithout causing an overheat. The user can set 10 -> 50 degrees above the setpo in t to be an overheat conditi on.
The default for the plenum
temp is 20F and the default for the grain temp is 30F.
6) The low level rotary switch function is the same as it was in 2.14, but now instead of giving a warning which states "DRY
CHAMBER EMPTY " whe n
it become s un c overed it gives "LOW LEVE L SW EXPOSED ."
7) Added an Out of Grain Timer. The time value can be changed under the setup but ton. This timer starts whenever either fill
systems is running and the load
switch is in the auto position. The timer is reset when both load augers stop. If the timer runs out of time an OUT OF GRAIN
warning is issued. The
default is 20 minutes. Any time the value of this Timer is change d th e new val ue takes effect immediately.
8) Changed warning for wet bin empty to state "WET BIN SW EXPOSED" instead of saying “DRYER OUT OF GRAIN”.
9) Renamed "FILL 1 DE LAY" to "FIL L SY S TE M #1 ". Changed name of "FILL 2 DELAY" to "HI LEVEL SW". The HI
LEVEL SW delay is always
available on both one and two fill sys t em dr yers and is used to make sure the dryer is full s o you don't get bogus shu t downs. The
FILL SYSTE M #1 delay is
only available when you are set for two fill systems and it is use d to es ta blish auger cleanout time.
10) If the Storage Bin Hig h Lim i t is det ected as failed (the N.C. pin and the N.O. pin from the swit ch are both reporting the sam e
voltage, 0 or 12 volts) a
warning is reported as “BIN HI LIMIT SW BAD”.
11) If wet supply rotar y switch becomes unco ver e d t her e i s a tim er w hi ch m us t expire before a warni ng is given. This timer/delay
was called "AUX 1 DELAY",
but is now termed "WET BIN SW. delay" It is found under t he DELAYS key.
12) The time a user has to think about making a chang e to a timer/setpoint bef or e i t au tomatically proceeds to the next selection
screen has been doubled.
13) Changed the name of de lay/timer "LOW LEVEL TIMER" to "LO L EVEL SWITCH."
14) Enabled the "START FANS WITH HIGH" switch function. There was previously a screen available to select this function, but
it was never active.
15) The cool down timer is now set to the reload valu e of the cool timer whenever any one of the four foll ow i ng s hutdowns takes
lace:
i) Dry and Hold swit c h i s turned to on state. ii) Grain falls awa y from wet bin supply switch.
iii) Storage chamber is full. iv) Dryer is o ut of gr ain.
16) Fans Off Delay now defaults to 0 minutes i nstead of 1 minute and has an upper limit of 5 minutes. This delay can be f ound
under the “delay” key.
17) The dryer functions the same whether the l oad s w i tch is in auto or on, but the o ut of gr ai n timer only times dow n while the load
switch is in the auto position
and one of the load a ugers i s run ni ng.
*********************************************************************
VERSION: 2.14 REVISED BY: Steve Logue RELEASE DATE: Sept 20, 2002
OTE: This Version does NOT support Wat chdog and the Heater Version MUST be 1.09 not the Watchdog version 1.10.
1) Fixed software so the bur ner differential could be set to one degre e a nd i t would remain there after loss of power.
-> Enabled means you will get a shutdown when a fan loses airflow. Disabled will satisfy the dryer's airflow
-> Enabled mea ns th e dr ying chamber low level sw itch will act as normal, i.e, w ill in dicate the real
-> Enabled means this switch will act as normal. Disabled means the dryer will think this switch is
HIGH -> Enabled means the dryer will start f ans according to state of dr ying chamber hi level switch.
-> Enabled means the B Y PASS is active, which all ows t he aer at ion fan to continue to ru n af ter a
12
Loading...