GSI PNEG-1885 User Manual

PNEG-1885

Special 105' 2 Ring Door for
Use with Enhanced Stiffeners
in

3rd and 4th Ring

Assembly Instructions

PNEG-1885

Date: 06-28-12

All information, illustrations, photos and specifications in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any
time without notice.

2 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

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 Installation Instructions ....................................... ..............................................................................14

Special 105' 2 Ring Door Instructions ....... ... .... ... ... ... .... ... .......................................... ... ... ................... 14

Door Placement...................................................................... ......................................... ................ 14

Jamb Plate Assembly...................................................................................................................... 15

Inner Door Assembly .......................................................................................................................16

Outer Door Assembly.......................................................................................................................19

Sidewall and Stiffener Door Attachment.......................................................................................... 21

Chapter 5 Warranty ..............................................................................................................................................25

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 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-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

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-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 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.

6 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

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-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 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

Respirator

Hard Hat

Fall Protection

8 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

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 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-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 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.

10 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

3. Safety Decals

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

CAUTION!

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

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 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: [phone]

12 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

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: [phone]

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 13

4. Installation Instructions

Special 105' 2 Ring Door Instructions

IMPORTANT: This GSI commercial 2 ring door is designed for use in the 2.66" corrugation 105' diameter

NCL tank. This door should not be installed in any tank not manufactured by GSI.

Door Placement

The commercial 2 ring door is installed in the bottom 2 rings. The door should normally be placed in line
with the conveyor. The center of the door must be positioned directly below the vertical seam of the ring
above it. The door can not be assembled properly, if the vertical seam is offset to one side of the door.
An intermediate discharge well should be located near the wall to clear grain from the area of the access
door. The two (2) anchor bolts for the door should be drill in anchor bolts placed after assembly of

the door. See “sidewall and stiffener door attachment” section on Page 23 for more details on the
anchor bolts.

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 stiffe ners in the door
placement area to place the inside frame weldment. A long and short special door sidewall sheets are sent
with the 2 ring door. See Figure 4A for door placement and special sidewall sheet usage.

Figure 4A

14 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

4. Installation Instructions

Jamb Plate Assembly

The jamb plates are bolted between the inner and outer door frame weldments (NCWT0439 (outer) and
NCWT0052 (inner)). The left jamb plate (NCWT0057L) has a “L” cut out in the plate. See Figure 4B
for “L” detailed orientation. The jamb plates bolt to the frame weldments using 7/16" x 2-1/2" bin bolts
(S-9444) and special recessed nuts (S-8479). Bolt heads should be orientated to outside of bin.

Figure 4B

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 15

4. Installation Instructions

Inner Door Assembly

The inner door hinges (NCWT0122) are bolted to the inner door frame weldment. (See detail B in

Figure 4C.) Using the 7/16" x 2-1/2" bolts that assemble the door frames together.

The 2 ring door requires eight (8) total latch bar holders (WD-6234) assembled to the inner door frame
weldment. Washers will be used to adjust the distance between the frame and the latch bar holder for the
best fit of the inner doors. Use 1/2" washers (S-2120) and 1/2" x 1-1/2" bolt (S-3728) to secure the latch
bar holders (WD-6234). (See detail A in Figure 4C.)

The 2 ring door requires eight (8) total bearing pins (WD-6224) to be used. Attach th e bearing pin s to the
inner door weldment using 5/16" x 1-1/2" bolts (S-2741), washer (S-845) and flange nut (S-3611). The
bearing pins should be attached at the eight (8) slots in the inner face of the weldment as shown in

Figure 4C. Leave the bearing pins loose until inner doors have been mounted to ensure a better fit.

Tighten the bearing pins once the inner doors are attached.

Figure 4C

16 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

4. Installation Instructions

Inner Door Assembly (Continued)

Figure 4D shows the hinge and handle assembly onto the upper and lower inner doors. Note the hinge

orientation in detail C of Figure 4D. 5/16" x 3/4" Bolts (S-275) and nuts (S-396) are used at most
attachment points. See Figure 4D for 5/16" x 1-1/4" bolt (S-277) and 5/16" x 3/4" truss head bolt
(S-4303) usage. Note usage of latch bushing (WD-6040) where the right hand and left hand latches
(WD-6037 and WD-6038) connect to the reinforcement angle (NCWT0158). The right and left hand
latches should be placed inside the reinforcement angles and attached using 5/16" lock nuts (S-5220).

Figure 4D

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 17

4. Installation Instructions

Inner Door Assembly (Continued)

The upper and lower door assemblies can now be assembled to the inner door weldment. Attach the
door assemblies to the hinges using 3/8" x 4-1/2" bolts (S-1443), nuts (S-456) and washers (S-248).
Adjust bearing pins and latch bar holders for best fit and tighten all bolts. (See Figure 4E.)

Figure 4E

18 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

4. Installation Instructions

Outer Door Assembly

Attach three (3) reinforcement channels (NCWT0162), two (2) hinges (NCWT0170) and two (2) retaining
brackets (WD-033) to the outer door cover with decals (NCWT0161D). Decals should be orientated
to inside of bin. Apply foam seal strip (S-8610) all along outer cover to seal tank.
bolt usage.

See Figure 4F

for

Figure 4F

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 19

4. Installation Instructions

Assembled outer cover

(See Figure 4F on Page 19.)

Outer Door Assembly (Continued)

Attach outer cover angle (NCWT0168) to the outer door weldment using 5/16" x 1-1/4" bolts (S-277),
nuts (S-396) and washers (S-845) for all connections. Attach hinge weldment (NCWT0165) an d latch plate
(NCWT0166) to outer cover angle (NCWT0168). See detail D in Figure 4G for orientation. The outer cover
then attaches to the hinges with 3/8" x 4-1/2" bolt (S-1443), nuts (S-456) and washers (S-248).

Figure 4G

20 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

4. Installation Instructions

Sidewall and Stiffener Door Attachment

Attach seal weldment (NCWT0258) to the inner and outer door weldments using eight (8) 3/8" x 1"
standard bolt (S-7469), special sealing washer (S-10102) and nut (S-456). (See Figure 4H.)

Figure 4H

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 21

4. Installation Instructions

Sidewall and Stiffener Door Attachment (Continued)

Attach sidewall to outside of jamb plates. Use 7/16" x 2-1/2" (S-9444) bin bolt and recessed nuts
(S-8479) to attach sidewall to jamb plates. Place corrugated sealing strip (CWT-0053) between outer
and inner edges of the sidewall to jamb plate connection. Caulk around the sealing strip and around the
sidewall to header connection as well. (See Figure 4I.)

Figure 4I

22 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

4. Installation Instructions

Sidewall and Stiffener Door Attachment (Continued)

Position 2 ring door stiffener weld (NCWT0218) under base stiffener sitting on top of 2 ring door header.
Attach header, base stiffer and 2 ring door stiffener together with 3/4" x 5" full threaded bolt (S-7324),
anchor bolt washer (HT-635), washer (S-866) and nut (S-234). (See detail F in Figure 4J.)

After all final adjustments to the door have been made, the anchor bolts should be drilled in place
through the external frame. GSI recommends Hilti 1" x 12" H.A.S. threaded anchor and 1" x 8-1/4" H.V.U.
adhesive capsules. (For seismic or special situation tanks, consult GSI engineering.)

Figure 4J

PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 23

NOTES

24 PNEG-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring

5. 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-1885 Special 105' 2 Ring Door for Use with Enhanced Stiffeners in 3rd and 4th Ring 25

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: [phone]

Fax: [phone]

www.gsiag.com

CN-300007