GSI PNEG-1708 User Manual
PNEG-1708
GSI Modular Tower Dryer
TM-1008, TM-1010, TM-1012 and TM-1015
Construction Manual
PNEG-1708
Date: 08-01-11
2 PNEG-1708 GSI Modular Tower Dryer
Table of Contents
Contents
Chapter 1 Introduction .......................................................................................................................................... 4
Chapter 2 Safety ..................................................................................................................................................... 5
Safety Guidelines .................................................................................................................................. 5
General Safety Statement ..................................................................................................................... 6
Electrical Power Supply ........................................................................................................................ 6
Chapter 3 Safety Decals ........................................................................................................................................ 7
Safety Decal # DC-GBC-1A ................................ ... ... .... ... ... ... .... ... ... ... .................................................. 8
Safety Decal # DC-1943 ....................................................................................................................... 9
Safety Decals # DC-985, DC-990 and DC-991 ................................................ ... ................................ 10
Safety Decals # DC-987, DC-988 and DC-989 ................................................ ... ................................ 11
Safety Decals # DC-1061 and 420-1473-8 ......................................................................................... 12
Safety Decals # DC-1063 and DC-1064 ............................................................................................. 13
Information Decals .... ... ....................................................................................................................... 14
Chapter 4 Dryer Overview and Specifications .................................................................................................. 15
Dimensions and Capacities for all Models .......................................................................................... 18
Dimensions - TM-1008 ........................................................................................................................ 19
Dimensions - TM-1010 ........................................................................................................................ 20
Dimensions - TM-1012 ........................................................................................................................ 21
Dimensions - TM-1015 ........................................................................................................................ 22
Chapter 5 Required Tools and Critical Tool Characteristics ........................................................................... 23
Critical Tool Characteristics ................................................................................................................ 23
Comprehensive Tool List .................................................... ... .... ... ... ... ... ............................................. 28
Chapter 6 Unloading and Staging the Modules ................................................................................................ 29
Chapter 7 Placing and Installing the Base/Unload Module .............................................................................. 30
Base/Unload Module Placement Considerations ................... ....................................... ... ... .... ... ......... 30
Securing the Unload Module ............................................................................................................... 32
Chapter 8 Assembling Ladders, Platforms and Catwalks ............................................................................... 34
Crate as Work Bench ................................... .... ... ... ............................................................................. 34
Installing Outside Ladder with Safety Cage ........................................................................................ 35
Overview Catwalk and Platform Assembly ......................................................................................... 39
Attaching Catwalks and Platforms to Dryer Modules .................... ... ... ... ....................................... ... ... 40
Chapter 9 Burner/Blower Module - Special Considerations ............................................................................ 48
Chapter 10 Lifting and Stacking the Modules ................................................................................................... 51
Overview for Safety ........................................................................................................................... 51
Recommended Stacking Order: Model 800 Series Dryer ................................................................. 52
Recommended Stacking Order: Model 1010 Series Dryer ............................................................... 53
Recommended Stacking Order: Model 1200 Series Dryer ............................................................... 54
Recommended Stacking Order: Model 1500 Series Dryer ............................................................... 55
Lifting ................................................................................................................................................. 56
Chapter 11 Electrical Connections ................................. ...................... ....................... ....................................... 64
Electrical Overview Minimal Connections .......................................................................................... 64
Air Switch ....................................................................................................................
Flame Sensor and Ignitor Wires (Spark Plug) ................................................................................... 67
Bindicator, Outside Overheat and Moisture Sensor .......................................................................... 69
Plenum Temperature ............................... ... .......................................... .... ... ...................................... 70
....................... 65
Chapter 12 Gas Pipe Train Overview ................................................................................................................. 71
Gas Pipe Train (Natural or LP) Overview Minimal Connections ..... ....................... ...................... ...... 71
Chapter 13 Finishing Touches: Removing Wrinkles and Dents from Screens .............................................. 73
Chapter 14 Warranty ............................................................................................................................................ 75
PNEG-1708 GSI Modular Tower Dryer 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.
4 PNEG-1708 GSI Modular Tower Dryer
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-1708 GSI Modular Tower Dryer 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 tower drye r. This manu al 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 precautions 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 tower dryer 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 tower dryer site should also be reviewed and considered. Any electrical control equipment in contact
with the tower dryer 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 drying. 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.
NOTE: A careful operator reduces risk of personal injury and equipment damage.
Electrical Power Supply
GSI recommends you contact your local power company and request that a representative inspect the
dryer installation. Be sure the wiring is compatible with the power company’s system and that adequate
power is supplied to the dryer.
6 PNEG-1708 GSI Modular Tower Dryer
3. Safety Decals
Some of the required safety decals are placed on the dryer before shipping. The remainder are placed on
the dryer during electrical installations. The purpose of the safety decals is to immediately alert all
personnel to the hazards of an operating dryer. The safety decal does not replace the need for all
personnel to know and understand safe dryer operations and requirements. Read the “Dryer Operations
and Service Manual”.
NOTE: Safety decals should be read and understood by all people in or around the dryer area.
Safety decals on Pages 8-13 identify and give the location of all safety decals that should be on each tower
dryer. Safety decals are listed in numerical order.
If the safety decals on the following pages are not on the dryer, or if they are damaged, immediately
contact GSI for replacement safety decals.
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 1-217-226-4421
PNEG-1708 GSI Modular Tower Dryer 7
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
Tower roof access port with decals in place.
Inside view - Access port installed with
decals in place.
Outside view - Access port installed with
decals in place.
Safety Decal # DC-GBC-1A
Location of Decals
English and spanish decals are placed on inside of tower roof access port before shipping.
8 PNEG-1708 GSI Modular Tower Dryer
Safety Decal # DC-1943
Example - Electrical control system
Location of Decal
On outside of main power box and inside main power box door.
3. Safety Decals
PNEG-1708 GSI Modular Tower Dryer 9
HIGH VOLTAGE.
Will cause injury
or death.
Lockout power
before servicing.
HAUTE TENSION.
Causera des
blessures ou la
mort.
Bloquez le courant
avant de faire
l’entretien.
DC-1943
3. Safety Decals
Safety Decals # DC-985, DC-990 and DC-991
Location of Decal
Inside main power box door, on same side as main electrical disconnect.
10 PNEG-1708 GSI Modular Tower Dryer
Safety Decals # DC-987, DC-988 and DC-989
Location of Decal
Inside main power box door, on same side as main electrical disconnect.
3. Safety Decals
PNEG-1708 GSI Modular Tower Dryer 11
3. Safety Decals
Flame and pressure
beyond door. May
cause serious injury.
Do not enter when
dryer is running.
WARNING!
DC-1061
Safety Decals # DC-1061 and 420-1473-8
Location of Decal
On outside of heat module door.
12 PNEG-1708 GSI Modular Tower Dryer
420-1473-8
Safety Decals # DC-1063 and DC-1064
High speed belt drive
operating overhead.
Can cause serious injury.
Keep head and hands
clear. Do not enter when
dryer is running.
WARNING!
DC-1064
Location of Decal
On outside of cool module door.
3. Safety Decals
PNEG-1708 GSI Modular Tower Dryer 13
CAUTION!
Airborne particles during
operation. May impair
vision and breathing.
Do not enter when
dryer is running.
DC-1063
3. Safety Decals
Example - Information decal
Information Decals
Nameplate for Main Power Box
Location of Decal
Inside main power box door, on same side as main electrical disconnect.
14 PNEG-1708 GSI Modular Tower Dryer
4. Dryer Overview and Specifications
All models of the GSI Modular Tower Dryer include a base/unload module, a burner/blower module,
a roof module and one or more heat modules. Heat modules can be “empty” or with turners based on
owner preference.
Module 1 on ALL models.
NOTE: New dryers ship with corrugated sheets.
Figure 4A Base/Unload Module
Figure 4B Burner/Blower Module
PNEG-1708 GSI Modular Tower Dryer 15
4. Dryer Overview and Specifications
Figure 4C Heat Module - w/ Turners
Figure 4D Empty Heat Module
16 PNEG-1708 GSI Modular Tower Dryer
4. Dryer Overview and Specifications
Figure 4E Heat Module - w/ Door Kit
Figure 4F Roof Module
PNEG-1708 GSI Modular Tower Dryer 17
4. Dryer Overview and Specifications
Dimensions and Capacities for all Models
There are four (4) models of the GSI Modular Tower Dryer. Each model is 10' 10" in diameter.
1. TM-1008
2. TM-1010
3. TM-1012
4. TM-1015
Model TM-1008 TM-1010 TM-1012 TM-1015
900 1125 1350 1690
BPH Capacity (20%-15%) 542 670 720 1010
BPH Capacity (25%-15%) 800 1000 1200 1500
BPH (Set in Maximum Cool) (20%-15%) 480 600 720 900
BPH (Set in Maximum Cool) (25%-15%) 900 1125 1350 1690
18 PNEG-1708 GSI Modular Tower Dryer
Dimensions - TM-1008
M-1008T - Five (5) modules total, usually
ships on two (2) trucks. All five (5)
modules are 10'-10" in diameter.
The 1008 model includes a platform at the base/unload,
ladders and safety cages to a stepover platform,
ladders and safety cages to a full catwalk and ladders
and safety cages to the roof access.
Module - 1 Base/unload
(See Figure 4A on Page 15.)
Module - 2 Heat module - burner/blower
(See Figure 4B on Page 15.)
Module - 3 Heat module - w/ door kit
(See Figure 4E on Page 17.)
Module - 4 Heat module - w/ turners
(See Figure 4C on Page 16.)
Module - 5 Roof module
(See Figure 4F on Page 17.)
Total weight = 18000 lbs.
NOTE: Please refer to Page 51 for individual section weights.
4. Dryer Overview and Specifications
Figure 4G TM-1008
PNEG-1708 GSI Modular Tower Dryer 19
4. Dryer Overview and Specifications
M-1010T - Six (6) modules total, usually
ships on two (2) trucks. All six (6)
modules are 10'-10" in diameter.
The 1010 model includes a platform at the
base/unload, ladders and safety cages to three (3)
full catwalks and ladders and safety cages to the
roof access.
Module - 2 Heat module - burner/blower
(See Figure 4B on Page 15.)
Module - 1 Base/unload
(See Figure 4A on Page 15.)
Module - 3 Heat module - w/ door kit
(See Figure 4E on Page 17.)
Module - 6 Roof module
(See Figure 4F on Page 17.)
Module - 5 Heat module - empty
(See Figure 4D on Page 16.)
Module - 4 Heat module - w/ turners
(See Figure 4C on Page 16.)
Total weight = 21645 lbs.
NOTE: Please refer to Page 51 for individual section weights.
Dimensions - TM-1010
Figure 4H TM-1010
20 PNEG-1708 GSI Modular Tower Dryer
Dimensions - TM-1012
M-1012T - Seven (7) modules total, usually
ships on three (3) trucks. All seven (7)
modules are 10'-10" in diameter.
The 1012 model includes a platform for the
base/unload module, ladders and cages to a full
catwalk stepover platform, ladders and cages to
three (3) catwalks and ladders and cages to the
roof access.
Module - 1 Base/unload
(See Figure 4A on Page 15.)
Module - 2 Heat module - burner/blower
(See Figure 4B on Page 15.)
Module - 3 Heat module - w/ door kit
(See Figure 4E on Page 17.)
Module - 4 Heat module - empty
(See Figure 4D on Page 16.)
Module - 6 Heat module - empty
(See Figure 4D on Page 16.)
Module - 7 Roof module
(See Figure 4F on Page 17.)
Total weight = 23095 lbs.
Module - 5 Heat module - w/ turners
(See Figure 4C on Page 16.)
NOTE: Please refer to Page 51 for individual section weights.
4. Dryer Overview and Specifications
PNEG-1708 GSI Modular Tower Dryer 21
Figure 4I TM-1012
4. Dryer Overview and Specifications
Module - 5 Heat module - w/ turners
(See Figure 4C on Page 16.)
M-1015T - Eight (8) modules total, usually
ships on three (3) trucks. All eight (8)
modules are 10'-10" in diameter.
The 1015 model includes a platform for the
base/unload module, ladders and cages to a
full catwalk stepover platform, ladders and
cages to three (3) catwalks and ladders and
cages to the roof access.
Module - 1 Base/unload
(See Figure 4A on Page 15.)
Module - 2 Heat module - burner/blower
(See Figure 4B on Page 15.)
Module - 3 Heat module - w/ door kit
(See Figure 4E on Page 17.)
Module - 4 Heat module - empty
(See Figure 4D on Page 16.)
Module - 7 Heat module - empty
(See Figure 4D on Page 16.)
Module - 6 Heat module - empty
(See Figure 4D on Page 16.)
Module - 8 Roof module
(See Figure 4F on Page 17.)
Total weight = 24545 lbs.
NOTE: Please refer to Page 51 for individual section weights.
Dimensions - TM-1015
22 PNEG-1708 GSI Modular Tower Dryer
Figure 4J TM-1015
5. Required Tools and Critical Tool Characteristics
Equipping the field crew with the right tools is essential for a smooth installation. The GSI Modular
Tower Dryer requires a number of standard tools. Please pay particular attention to the following item
descriptions as the characteristics of the following tools are extremely important information for proper
installation. A comprehensive list of tools required to assemble and install the GSI Modular Tower Dryer
is included later in this chapter.
Critical Tool Characteristics
1. 1-1/8" Hammer drill star bit at least 12" long is REQUIRED. While the anchor bolts are 1" in
diameter, the holes for the anchor bolts MUST be 1-1/8" in diameter to allow room for the required
epoxy. Additionally, anchor bolts must be sunk deep enough so that no more than 2"-3" is above
the plate.
An air compressor hose is needed to blow out the dust from the holes prior to dropping in the anchor
bolts and epoxy. (See Figure 5A.)
2. Air compressor with hose: After drilled the holes for the anchor bolts, an air compressor with hose
is REQUIRED in order to blow all dust and debris out of the holes.
Figure 5A Anchor Bolts Sunk - No More than 3" Remains above Plate
3. Punches: 1/4" Line up punches - at least 8
5/8" line up punches - at least 8
Ideally, during the installation process, crews will work in two (2) person teams with one team working
inside the dryer and one team working outside the dryer. Each crew member should have at least
two (2) punches available to them.
Punches should be long enough to provide significant leverage to the user and should have narrow
and pointed tips to facilitate the initial punch placement. (See Figure 5B and Figure 5C on Page 24.)
PNEG-1708 GSI Modular Tower Dryer 23
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