GSI PNEG-1820 User Manual
PNEG-1820
CE Compliant Top Dry
Series 2000 Autoflow
Operators Manual
PNEG-1820
Date: 04-10-12
2 PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow
Table of Contents
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines .................................................................................................................................. 4
Fan/Heater Installation and Operating Instructions ............................................................................... 5
Safety Sign-Off Sheet ........................................................................................................................... 7
Chapter 2 Decals ....................................................................................................................................................8
Chapter 3 Fuel and Electrical Specifications ....................................................................................................11
Top Dry CE Heater Specifications ...................................................................................................... 11
Chapter 4 Electrical Installation .........................................................................................................................12
Machine to Earth Connection .............................................................................................................. 12
Emergency Stop ........................ ... .... ... .......................................... ... ................................................... 12
Chapter 5 Fuel Installation ..................................................................................................................................13
Fuel Supply ......................................................................................................................................... 13
Liquid LPG ................................... .... ... ... ... ... ....................................... ... .... ... ... ... .... ... ......................... 13
Vapor LPG ................................... .... ... ... ... ... ....................................... ... .... ... ... ... .... ... ... ...................... 13
Natural Gas ......................................................................................................................................... 13
Chapter 6 Control Panel ......................................................................................................................................14
Dryer Control Panel ............................................................................................................................. 14
Chapter 7 Control System ...................................................................................................................................16
Electronic Monitoring Control System ................................................................................................. 16
Chapter 8 Fill System Control Box .....................................................................................................................19
Chapter 9 Error Messages and Valve Proving System .......................................................................... ..........22
Error Messages ................................................................................................................................... 22
Valve Proving System ......................................................................................................................... 24
High Gas Pressure Switch .................................................................................................................. 24
Chapter 10 Initial Start-Up ...................................................................................................................................25
Dryer Commissioning ........................................................................................................................ 25
Chapter 11 Pre-Season Checks ..........................................................................................................................27
Set Control Switches ......................................................................................................................... 27
Control Power Switch ........................................... ... .... ... ... .......................................... ... ... ................ 27
Drying Chamber ................................................................................................................................ 28
Rotary Switches ................................................................................................................................. 28
Linear Actuator ..... ... ... ... .......................................... .... .......................................... ... ......................... 28
Power Start Button ............................................................................................................................ 28
Fuel Check ........................................................................................................................................ 28
Fan .................................................................................................................................................... 28
Aeration Fan ...................................................................................................................................... 28
Fill System .................................. .... ................................................................................................... 29
Air Switch ........................................................................................................................................... 29
Burner Test Fire ....................... ... .... ... .......................................... ... ................................................... 29
Dryer Shut Down ............................................................................................................................... 29
Emergency ........................................................................................................................................ 29
Chapter 12 Autoflow Theory ...............................................................................................................................30
Top Dry Autoflow Theory of Operation .............................................................................................. 30
Chapter 13 Start-Up Procedure ................................................................................................
Initial Dryer Start-Up .......................... ... ... ... .... ... .......................................... ... ................................... 32
Normal Start-Up ....................... ... .... ... .......................................... ... ................................................... 34
Last Fill .............................................................................................................................................. 34
Chapter 14 Warranty ............................................................................................................................................35
PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow 3
..........................32
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 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.
DANGER
WARNING
CAUTION
NOTICE
4 PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow
1. Safety
Fan/Heater Installation and Operating Instructions
Thank you for choosing a Top Dry Series 2000 Autoflow.
This manual describes the operation of CE Compliant Top Dry Series 2000 single fan, multi-fan heater
control units.
Our principal concern is your safety. This manual is written to help you understand safe operating
procedures for you and your co-workers.
As owner and/or operator, it is your responsibility to know that requirements, hazards and precautions
exist and to inform all personnel associated with the equipment or who are in the area.
Do not alter the equipment. Alterations may produce a very dangerous situation, where serious injury or
death may occur.
CE Compliance
This dryer has been designed to comply with EU Directives. Compliance depends upon the dryer being
constructed, installed and operated in accordance with GSI instructions.
General Safety
Before operating your Top Dry, please read and understand this manual.
Keep the manual available for operators and maintenance technicians.
Make sure all operators are aware of potential hazards, risks and safe operating procedures.
Never enter the dryer when it is operating.
The Top Dry is designed for drying agricultural corn, seeds and grain only.
To reduce the risk of fire, keep the dryer clean, paying special attention to the area around the fan
and heater.
Use only genuine GSI parts.
Never bypass any safety device or interlock.
Electrical Safety
Electrical connections and maintenance must be carried out in accordance with Local Codes and
Directives by qualified engineers only.
The dryer must be fitted with a suitable, lockable electrical shut off device (isolator).
Flammable Fuels
Fuel supply and connections must be made in accordance with Local Codes and Directives by qualified
gas fitters.
The fuel supply must include over pressure protection and a lockable manual isolator valve.
Check the fuel type is correct or the dryer and supply pressures meet the dryer requirements
Safety Guards
Safety guards must be fitted securely at all times when operating the dryer.
If a guard becomes damaged lease fit a genuine replacement before using the dryer.
PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow 5
1. Safety
WARNING
Drying flammable grains and seeds.
Safety in Maintenance
Shut off and lock power and fuel supply to the dryer before entering or carrying out service or maintenance.
Before entering the drying bin allow run the fan only for 20 minutes to purge products of combustion and
cool and heater components.
Ensure the grain chutes are empty by performing a manual dump before entering.
Before opening the fuel train safely de-pressurise the system.
Access to items at high level will require suitable safe access equipment, such as scaffold.
Dust
Dust may be created in the movement of corn, grain or seeds to and from the Top Dry. Use a
suitable respirator.
Noise
Sound levels around the fan and heater may exceed 80 dBa. Avoid working in this area and wear
hearing defenders.
FOR GUIDANCE OR ASSISTANCE ON ANY ISSUES RELATING TO THE SAFE USE OF THE TOP
DRY CONTACT:
GSI Group
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 1-217-226-4421
Exercise caution when drying highly flammable grains and seeds.
For example rapeseed, canola, linseed, sunflower and milo.
All grain and seed must be whole (minimal cracked or crushed), clean and dust free.
Dry at low temperatures (< 50°C).
Avoid dust and chaff being drawn into the fan and heater.
Keep the fan, heater, drying plenum and ducts clean at all times.
In the event of a fire (or suspected fire).
1. Shut down the entire dryer.
2. Turn OFF fuel at the tank or supply valve.
3. Shut off and lock electrical power.
4. Evacuate the area.
5. Call the fire department.
6 PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow
1. 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 auger. 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-1820 CE Compliant Top Dry Series 2000 Autoflow 7
2. Decals
Respirators
must be worn
in this area
No entry to
unauthorised
personnel
DC-2161
Isolate and lock all power
before entering this bin
Do not walk directly
on stored material
Before entering:
Disconnect and lock all electrical
power
Use safety harness and safety line
Ensure someone else is outside
the bin
Disconnect and lock fuel supply
Permit required for entry into
confined space
Suffocation and
Entrapment Hazard
Automatic Machinery
No smoking or
naked flames
DC-2161
Background: White
Colors: Black, ANSI Yellow, ANSI Blue and ANSI Red
Size: 8.860" x 5.910"
Do not operate with guards
removed
Isolate and lock from power
before removing guards
Replace all guards before
reconnection to power
Automatic
Rotating
Fan Blades
DC-2162
DC-2162
Background: White
Colors: Black, ANSI Yellow and ANSI Blue
Size: 3.940" x 1.970"
Safety decals must be read and understood by all people in and around the top dry area. If any safety
decals are not displayed on the top dry or if they are damaged, contact the GSI Group, Inc. for replace ment:
Decals
1004 E. Illinois St.
Assumption, IL. 62510
Phone: 1-217-226-4421
8 PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow
Isolate and lock from power
before removing guards or
opening enclosure
Replace all guards and lock
enclosure before reconnecting
to power
High
Voltage
DC-2163
DC-2163
Background: White
Colors: Black, ANSI Yellow and ANSI Blue
Size: 3.940" x 1.970"
Automatic
DC-2164
Background: White
Colors: Black, ANSI Yellow and ANSI Blue
Size: 3.940" x 1.970"
DC-2165
Do not open door while drier is
running
Disconnect and lock electric and
gas supply before opening
Close and lock door before
reconnecting
High Temperature
and Pressure
Equipment Can Start
Unexpectedly
DC-2165
Background: White
Colors: Black, ANSI Yellow and ANSI Blue
Size: 5.910" x 3.940"
Machinery
Do not operate with guards
removed
Isolate and lock from power
before removing guards
Replace all guards before
reconnection to power
DC-2164
2. Decals
PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow 9
2. Decals
DC-2166
Ear protection
must be worn
in this area
DC-2166
Background: White
Colors: Black and ANSI Blue
Size: 5.910" x 3.940"
NO YES
Use CENTRE OUTLET ONLY until NO
grain remains above the outlet
Failure to follow
these instructions
will result in
structural damage
or collapse
Side outlets to be used ONLY when this
condition is satisfied
Lock all side outlets to prevent incorrect use
DC-2210
DC-2210
Background: White
Colors: Black, ANSI Yellow, ANSI Blue and ANSI Red
Size: 5.910" x 3.940"
Automatic Machinery
May Start
Unexpectedly
Replace all guards before
reconnection to power
Isolate and lock from
power before removing
guards
Do not operate with
guards removed
DC-2211
DC-2211
Background: White
Colors: Black, ANSI Yellow and ANSI Blue
Size: 3.940" x 1.970"
10 PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow
Top Dry CE Heater Specifications
Fuel Specifications
3. Fuel and Electrical Specifications
LPG Gross CV = 98.37 MJ/m
kW
kW
Maximum
Air
3
/s m3/s
m
Maximum
Air
3
/s m3/s
m
Motor
Fan
36" 11.19 8.74 2.83 747.30 373.65 1311.91 495.30 420.00 16.00 9.74 50.31
40" 11.19 12.75 5.20 747.30 373.65 1786.16 674.19 420.00 16.00 11.37 68.50
42" 22.00 16.06 7.79 871.85 373.65 2635.04 994.10 420.00 28.00 13.80 101.06
42" 30.00 17.95 8.50 871.85 373.65 3119.11 1 177.21 420.00 28.00 15.02 119.62
Natural Gross CV = 38.6 MJ/m
Motor
Fan
36" 11.19 10.39 3.31 747.30 373.65 1311.91 495.30 420.00 16.00 12.04 122.26
40" 1 1.19 12.75 5.20 747.30 373.65 1786.16 674.19 420.00 21.00 14.05 166.46
42" 22.00 16.06 7.79 871.85 373.65 2635.04 994.10 420.00 28.00 17.06 245.56
42" 30.00 17.95 8.50 871.85 373.65 31 19.11 1177.21 420.00 27.00 18.56 290.68
3
Minimum
Air
3
Minimum
Air
Maximum
Static
Pa Pa kW kW mBar mBar mm
Maximum
Static
Pa Pa kW kW mBar mBar mm
Minimum
Static
Minimum
Static
Maximum
Heat
Maximum
Heat
Minimum
Heat
Minimum
Heat
Maximum
Burner
Pressure
Maximum
Burner
Pressure
Minimum
Burner
Pressure
Minimum
Burner
Pressure
Orifice
I.D.
Orifice
I.D.
Maximum
Gas
Flow
m3/h
Maximum
Gas
Flow
m3/h
Electrical Specifications
380 VAC 400 VAC
Fan
Motor
kW A A A A
36" 11.19 22.67 68.01 21.54 64.61
40" 11.19 22.67 68.01 21.54 64.61
42" 22.00 44.57 133.70 42.34 127.02
42" 30.00 60.77 182.32 57.74 173.21
Motor
Fan
kW A A A A
36" 11.19 22.67 68.01 21.54 64.61
40" 11.19 22.67 68.01 21.54 64.61
42" 22.00 44.57 133.70 42.34 127.02
42" 30.00 60.77 182.32 57.74 173.21
Maximum Current
Draw FLA
415 VAC 440 VAC
Maximum Current
Draw FLA
Maximum Start
Current
Maximum Start
Current
Maximum Current
Draw FLA
Maximum Current
Draw FLA
Maximum Start
Current
Maximum Start
Current
NOTE: When commissioning, check motor ratings on individual motors and set overloads accordingly.
PNEG-1820 CE Compliant Top Dry Series 2000 Autoflow 11
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