GSI PNEG-1743 User Manual
PNEG-1743
Vision for Tower Dryers
Operation Manual
PNEG-1743
Date: 05-12-10
2 PNEG-1743 Vision for Tower Dryers
Table of Contents
Contents
Chapter 1 Safety .....................................................................................................................................................5
Safety Guidelines .................................................................................................................................. 5
Dryer Operation ..................................................................................................................................... 6
Emergency Stop Switch ................................... ... ... ... .... ... ... ... .... ... ... ..................................................... 6
Operating Precautions ..................................... ... ... ... .... ... ... ... .... ... ........................................................ 7
Chapter 2 Decals ....................................................................................................................................................9
Chapter 3 Vision Control Panel ..........................................................................................................................11
Control Power Switch .......................................................................................................................... 11
Stop Button ......................................................................................................................................... 11
Outside Light Switch ........................................................................................................................... 12
Start Button ......................................................................................................................................... 12
Unload Switch ..................................................................................................................................... 12
Meter Roll Adjustment ......................................................................................................................... 12
Load Switch ..................... .... ... ............................................................................. .... ... ......................... 13
Fan Switch .......................................................................................................................................... 13
Heater Switch ...................................................................................................................................... 13
Chapter 4 Boot Screen ........................................................................................................................................14
Boot Screen Description and Button Explanations ............................................................................. 14
Software Update Procedure ............................. ................................................ ................................... 15
Chapter 5 Operations ..........................................................................................................................................19
Default Operation Screen .................................................................................................................... 19
Timers Button ...................................................................................................................................... 20
Load Delay .................................................................................. ... ... .... ... ... ... .... ... ......................... 20
Out Of Grain (OOG) Timer ............................................................................................................. 20
Fan Delay................ .......................................... ... .......................................... .... ............................ 20
Unload Delay..... ... ... ... .... ... ... .............................................................................. ... ... ... ................... 20
Cool Down.. ... .... ... ... ... .... ... ............................................................................. .... ... ... ... ................... 20
Temp Button ........................................................................................................................................ 21
Plenum Temperature Setpoint.................................. ... ... ... .... ... ... ... ... .... ... ... ... ................................ 22
Grain Temperature Setpoint........................................................................................................... 22
Setup Button ..................................... ... ... ... ... .... .......................................... ... ..................................... 23
Drying Mode...................................................................................... .... ... ... ... .... ... ... ... ................... 23
Moisture Control Setup................................ ... ... ... .... ... ... ... .......................................... ... ................ 24
Unload Parameters............................ ... ... .......................................... .... ......................................... 24
Plenum Temp Manager........ ... .......................................... .... ... ... ... ................................................ 25
Calibrate Moisture Sensor.............................................................................................................. 25
Extended Setup Screen.................................................................. ... .... ... ... ... ................................ 26
Diagnostics............................................................................................................................... 26
Differential ................................................................................................................................ 27
BPH Calibration........................................................................................................................ 27
Set Time/Date .......................................................................................................................... 28
Temp Scale.............................................................................................................................. 28
Dryer Model.............................................................................................................................. 28
Data Logger Setup....................................................................................................................29
User Saved Defaults ................................................................................................................ 30
View Button......................................................................................................................................... 30
Table View................................... ... ... ... ... .... ... ... ....................................... ... ... .... ... ... ... ................... 30
Select Data Log Sample Time...................................................................................................
Graph View. ... .... ... ... ... .... ... ... ... .... ... ... .......................................... ... ... .... ... ... ................................... 31
Owner’s Manual ................................ ... ... .... ... .......................................... ... ....................................32
Error History ............................................ .......................................... .... ..........................................32
System Information......................... ... .......................................... ... ................................................ 32
Software Version Info..................................................................................................................... 33
31
PNEG-1743 Vision for Tower Dryers 3
Table of Contents
M/C Button .......................................................................................................................................... 33
Modifying Temperature Setpoint ..................................................................................................... 33
Modifying Moisture Setpoint............................................................................................................ 34
Resetting Factory Defaults............. .... ... ... ... .......................................... ... .... ... ... ................................. 34
Chapter 6 Moisture Control Options ..................................................................................................................35
Continuous Flow Drying................. ....................................... ... .... ... ... ... ... .... ... .................................... 35
Temperature Controlled Schemes.................................................................................................. 35
Moisture Controlled Schemes ........................................................................................................ 39
Chapter 7 Initial Settings Check .........................................................................................................................42
Dealer Suggested Initial Settings Check ........... ... ... ... .... ... ... ... .......................................... ... .... ... .. ...... 42
Owner Suggested Initial Settings Check ....... .... .......................................... ... ... ... .... ........................... 42
Chapter 8 Safety Circuit Shutdown Messages ......................................................................... ... ......................43
Fan/Heater Shutdown Messages ........................................................................................................ 43
Main I/O Shutdown Messages .......................................................... ... ... .... ... ... ... .... ... ... ..................... 46
Moisture Control Shutdown Messages ............................................................................................... 48
Chapter 9 Warranty ..............................................................................................................................................49
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1. Safety
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 potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
NOTE indicates information about the equipment that you
should pay special attention.
DANGER indicates an imminently 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-1743 Vision for Tower Dryers 5
1. Safety
Emergency Stop
Pushing the Emergency Stop switch does not interrupt the main power to the
upper control box panel.
Dryer Operation
Thank you for choosing a GSI product. It is designed to give excellent performance and service for
many years.
This manual describes the operation for all standard production model dryers. These dryers are available
with liquid propane or natural gas fuel supply and 3 phase 230, 380, 460 or 575 volts (50 Hz or 60 Hz)
electrical power.
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 which 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 p roduce 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.
Emergency Stop Switch
The Emergency Stop switch is located on the upper control box door. Pushing the Emergency Stop switch
will interrupt the control power and stop all dryer functions.
6 PNEG-1743 Vision for Tower Dryers
1. Safety
Keep the dryer clean. Do not allow fine material to accumulate in the plenum
chamber or surrounding the outside of the dryer.
Operating Precautions
READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION
SAVE FOR FUTURE REFERENCE
1. Read and understand the operations manual before attempting to operate the unit.
2. Keep ALL guards, safety decals and safety devices in place. NEVER operate dryer while guards
are removed.
3. Keep visitors, children and untrained personnel away from dryer at all times.
4. Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on
the unit.
5. Always set the main power supply disconnect switch to OFF and lock it in the OFF position using
a padlock before performing any service or maintenance work on the dryer or the auxiliary
conveyor equipment.
6. Keep the dryer and wet holding equipment CLEAN. DO NOT allow fine material to accumulate.
7. On LP fired units, set pressure regulator to avoid excessive gas pressure applied to a burner
during ignition and when the burner is in operation. Do not exceed maximum recommended
drying temperatures.
8. DO NOT operate the dryer if any gas leak is detected. Shut d own and repair before further operation.
9. Clean grain is safer and easier to dry. Fine materials can be highly combustible, and it also requires
removal of extra moisture.
10. Use CAUTION in working around high-speed fans, gas burner, augers and auxiliary conveyors which
can START AUTOMATICALLY.
11. Be certain that capacities of auxiliary conveyors are matched to dryer metering capacities.
12. DO NOT operate in an area where combustible material will be drawn into the dryer.
13. The operating and safety recommendations in this manual pertain to the common cereal
grains as indicated. When drying any other grain or products, consult the factory for
additional recommendations.
14. Routinely check for any developing gas plumbing leaks.
15. Before attempting to remove and reinstall the fan blade, contact GSI for the recom mended procedu re.
Use Caution in the Operation of this Equipment
This dryer is designed and manufactured with operator safety in mind. However, the very nature of a grain
dryer having a gas burner, high voltage electrical equipment and high speed rotating parts, presents
hazards to personnel which cannot be completely safeguarded against without interfering with the efficient
operation of the dryer and reasonable access to its 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.
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 the Owner’s Manual
and make it a practice to regularly inspect the unit for any developing problems or unsafe conditions.
Take special note of the Operating Precautions before attempting to operate the dryer.
PNEG-1743 Vision for Tower Dryers 7
1. 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.
Long hair should be tied up and back.
Safety glasses should be worn at all times to protect eyes
from debris.
Wear gloves to protect your hands from sharp edges on
plastic or steel parts.
Wear steel toe boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoe strings.
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Wear 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 Toe Boots
Respirator
Hard Hat
Fall Protection
8 PNEG-1743 Vision for Tower Dryers
2. Decals
HIGH VOLTAGE.
Will cause serious
injury or death.
Lockout power
before servicing.
DC-1224
Decal: DC-889
Decal DC-889 has two locations. One inside the
fan/heater control box and another on the dryer upper
control box door next to the main power disconnect.
Decal: DC-1224
Decal DC-1224 is located in two places on the fan/heater control box. One on the
lid and one on the front of the fan heater control box. Another location for this
decal is inside the upper control box for the dryer.
Contact the local power company to have a representative survey the installation to assure the wiring is
compatible with their system and adequate power is supplied to the unit. Safety deca ls should be read and
understood by all people in the grain handling area. Inspect all decals and replace any that are
illegible, worn or missing. Contact your dealer or the factory to order replacement decals.
If a decal is damaged or is missing, contact:
GSI Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 1-217-226-4421
A free replacement will be sent to you.
NOTE: Decals are not shown actual size.
PNEG-1743 Vision for Tower Dryers 9
2. Decals
Flame and pressure
beyond door. May
cause serious injury.
Do not enter when
dryer is running.
DC-1061
WARNING!
Decal: DC-1062
Decal DC-1062 is located inside the cooling section of the dryer on the two
access doors to the metering section.
Decal: DC-1063
Decal DC-1063 is located on the louvered
access door to the cooling section of the dryer.
Decal: DC-1064
Decal DC-1064 is located on the louvered access
door to the cooling section of the dryer.
Decal: DC-1061
Decal DC-1061 is located on the outside
of the heat section door.
DO NOT STAND ON DRUM!
Rotating drum will cause
serious injury or death.
Disconnect power before
servicing.
DC-1062
Airborne particles during
operation. May impair
vision and breathing.
Do not enter when
dryer is running.
DC-1063
WARNING!
High speed belt drive
operating overhead.
Can cause serious injury.
Keep head and hands
clear. Do not enter when
dryer is running.
DC-1064
10 PNEG-1743 Vision for Tower Dryers
3. Vision Control Panel
Fan switches
Load switch
Unload switch
Outside
Light switch
Control
Power switch
Stop button
Start switch
Meter Roll
Adjustment
Touch screen
Heater switches
Control Power Switch
The Vision control system is turned ON or OFF with this switch.
NOTE:
Stop Button
This button stops all dryer functions except the blower (fan). If the blower switch, noted on the panel as
the Fan switch, is in the ON position, the blower will continue to run for 15 minutes. If you desire the
blower to be OFF, turn the blower switch to the OFF position. If an automatic dryer shutdown occurs,
first determine and correct the cause of the shutdown. Then, press the Stop button to reset the dryer
before restarting.
PNEG-1743 Vision for Tower Dryers 11
Figure 3A
This switch does not disconnect the power that is present at the breakers, contactors, transformer(s),
fuses or other electrical components found in the control or power box. Turn the main disconnect
handle to the OFF position prior to servicing any of the installed components.
3. Vision Control Panel
Outside Light Switch
The dryers outside service light is turned ON or OFF here. It also can be set on AUTO, which turns the
light ON while the dryer is running and OFF if a shutdown occurs.
Start Button
Push the Start button and all of the selector switches on the control panel will be activated.
Unload Switch
The Unload switch turns the metering rolls and discharge auger ON or OFF and selects the operation of
the metering rolls. In the MANUAL position, the meter rolls will operate in one Speed only. In the AUTO
position, the meter rolls switch to a multi-speed mode for moisture control operation. The switch will
illuminate whenever the load auger is operating.
NOTE: If the unload auxiliary controls are being used, this switch will also control the operation of the
auxiliary equipment.
Meter Roll Adjustment
This knob allows the user to adjust the meter roll setpoint(s). Pressing the knob will bring up the “Modifying
Meter Roll Speed Setpoints” screen. (See Figure 3B.)
Figure 3B
NOTE: Screen may vary depending on the moisture control scheme selected.
Turning the knob clockwise will adjust the selected (red color) setpoint in a positive direction and vice
versa. Pressing the knob will switch between setpoints.
12 PNEG-1743 Vision for Tower Dryers
3. Vision Control Panel
Load Switch
This is used to select the operation of the fill auger. In both the AUTO and MANUAL positions, the load
auger will operate if the dryer is low on grain and will automatically shut OFF when the dryer is full. In the
AUTO position, the dryer will shutdown if the out of grain timer expires. The load delay is disabled
when the Load switch is in the MANUAL position. The switch will illuminate whenever the load auger
is operating.
Fan Switch
The fan is turned ON or OFF with this switch. Turning the switch to the ON position will turn the fan
ON. Turning the switch to the OFF position turns the fan OFF. The light inside the switch will illuminate
whenever the air pressure sensor detects air movement through the fan.
NOTE: The fan AUTO position is not used for continuous flow operation.
Heater Switch
The burner (heater) is turned ON or OFF with this switch. Turning the switch to the ON position will
start the burner ignition sequence if the fan is also running. Turning the switch to the OFF position turns
the burner OFF. The light inside of the switch will illuminate only when the flame sensor detects the
burner flame.
NOTE: The heater AUTO position is not used for continuous flow operation.
PNEG-1743 Vision for Tower Dryers 13
4. Boot Screen
Boot Screen Description and Button Explanations
Turning the Control Power switch to the ON position, will start the Vision computer. The first screen to
appear will be the Boot Screen. Notice that there are four (4) buttons on the Boot Screen. (See Figure 4A.)
Figure 4A
1. Start Dryer: This button accesses the dryer program.
2. Install Dryer Software: This button is used in updating the Vision software, which is described
further in this chapter.
3. Get Program From USB Flash: This button is used in updating the Vision software, which is
described further in this chapter.
4. Exit To Windows: This button should NOT be used in normal operation. Only the GSI Group
employees should press this button. Turn the Control Power switch OFF, then ON if this button is
inadvertently pushed to return to the regular Boot Screen.
14 PNEG-1743 Vision for Tower Dryers
Software Update Procedure
Control
Power switch
Get Program From
USB Flash button
1. Cycle the Control Power switch. The Vision computer will start. (See Figure 4B.)
4. Boot Screen
Figure 4B
2. When the “Boot Screen” appears, touch the “Get Program From USB Flash” button. (See Figure 4C.)
PNEG-1743 Vision for Tower Dryers 15
Figure 4C
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