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PNEG-634
User Manual
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GSI PNEG-634 User Manual

PNEG-634
2003 Series 2000 Batch Fan/Heater and Control Installation Instructions
Installation Manual
PNEG-634
Date: 03-21-11
This equipment shall be installed in accordance with the current INSTALLATION CODES FOR GAS BURNING APPLICANCES AND EQUIPMENT, CAN1_B149.1 and B149.2 or applicable provincial regulations which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
Table of Contents

Contents

Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines ... ... ... ... .... .................................................................................................................. 4
Fan/Heater Installation and Operating Instructions ............................................................................... 5
Safety Precautions . ... ... .......................................... ... .... ... ... ... .... ... ... ..................................................... 5
Safety Sign-Off Sheet ........................................................................................................................... 7
Chapter 2 Decals ....................................................................................................................................................8
Chapter 3 Installation ..........................................................................................................................................10
Fan/Heater Mounting ....................................... ... ... ... .............................................. ............................ 10
Control Box Mounting .......................................................................................................................... 10
Grain Temperature Sensor Installation ............................................................................................... 12
Master Heater Control Box .................................................................................................................. 14
Multi-Grain Temperature Sensor ............ ... ... .... ... ... ... .... ... ............................................. ...................... 15
Plenum High-Limit Installation ............................................................................................................. 16
Top Dry Plenum High-Limit Installation ............................................................................................... 17
Plenum Temperature Sensor .............................................................................................................. 18
Drying Chamber Overflow Rotary Switch ............................................................................................ 19
Storage Chamber High-Limit Rotary Switch ....................................................................................... 21
Liquid Propane (LP) ........ .... ... ... ... .... ... ... ... ... .... .......................................... ... ... ... .... ... ... ... ................... 23
Natural Gas (NG) ................................................................................................................................ 24
Chapter 4 Electrical Power Supply .....................................................................................................................25
Power Supply ...................................................................................................................................... 25
Transformer and Wiring Voltage Drop ................................................................................................ 25
Machine to Earth Grounding ............................................................................................................... 25
Proper Installation of Ground Rod ....................................................................................................... 26
Power/Motor Wiring ...................... .... ... ... ... ... ....................................................................................... 28
Electrical Load Information .................................................................................................................. 29
Stand Alone Fan/Heater ............................ ... .... ... ... ... .... ... ... ... .... ... ... ................................................... 30
Economy Control Center Interconnect ................................................................................................ 31
Manual Control Center Interconnect ................................................................................................... 32
Master to Slave Interconnect ................................. ... .... .......................................... ... ... ... ... .... ............ 33
Slave to Slave Interconnect ................................................................................................................ 34
Rotary Switch and Horn Wiring ........................................................................................................... 35
Chapter 5 Warranty ..............................................................................................................................................37
PNEG-634 2000 Top Dry Fan/Heater 3

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.
Personnel operating or working around equipment should read this manual. This manual must be delivered with the equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment.
WARNING! BE ALERT!
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
1. Safety
Fan/Heater Installation and Operating Instructions
Thank you for choosing a Top Dry Series 2000 Fan/Heater unit. It is designed to give excellent performance and service for many years.
This manual describes the installation for all standard production Top Dry Series 2000 single fan, multi-fan and 2000 series heater control units. Different models are available for liquid propane or natural gas fuel supply, with either 1 phase 230 volt or 3 phase 208, 220, 380, 460 or 575 volt 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 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.
Safety Precautions
READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE
SAVE FOR FUTURE REFERENCE
1. Read and understand the operating manual before trying to operate the dryer.
2. Power supply should be OFF for service of electrical components. Use CAUTION in checking voltage or other procedures requiring power to be ON.
3. Check for gas leaks at all gas pipe connections. If any leaks are detected, DO NOT operate the dryer. Shut down and repair before further operation.
4. NEVER attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit.
5. Set pressure regulator to avoid excessive gas pressure applied to burner during ignition and when burner is in operation. DO NOT exceed maximum recommended drying temperature.
6. Keep the dryer clean. DO NOT allow fine material to accumulate in the plenum or drying chamber.
7. Use CAUTION in working around high speed fans, gas burners, augers and auxiliary conveyors which can START AUTOMATICALLY.
8. DO NOT operate in any area where combustible material will be drawn into the fan.
9. BEFORE attempting to remove and re-install any propeller, make certain to read the recommended procedure listed within the servicing section of the manual.
10. Clean grain is easier to dry. Fine material increases resistance to airflow and requires removal of extra moisture.
This product is intended for the use of grain handling only. Any other use is considered a misuse of the product.
Some edges of the product components can be sharp. It is recommended that each component of this product be examined to determine if there are any safety considerations to be taken. Any and all necessary personal protective equipment should be worn at al l times wh en handling, assembling, installing and operation of the product and/or components. Guards are removed for illustration purpose only. All guards must be in place before/during operation.
PNEG-634 2000 Top Dry Fan/Heater 5
1. Safety
CAUTION
Keep the dryer clean. Do not allow fine material to accumulate in the plenum chamber or surrounding the outside of the dryer.
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 withou t 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 this manual and make it a practice to regularly inspect the unit for any developing problems or unsafe conditions.
Take special note of the Safety Precautions on Page 5 before attempting to operate the dryer.
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 equipment. 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-634 2000 Top Dry Fan/Heater 7

2. Decals

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
CAUTION!
The GSI recommends contacting your local power company and having a representative survey the installation so the wiring is compatible with their system and adequate power is supplied to the unit.
Safety decals should be read and understood by all people in the grain handling area. The rotating blade, fire warning decals and voltage danger decal must be displayed on the fan can. The decal DC-GBC-1A shown on Page 9 should be present on the inside bin door cover of the 2 ring door, 24" porthole door cover and the roof manway cover.
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.
Roof Damage Warning and Disclaimer
The manufacturer does not warrant any roof damage caused by excessive vacuum 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 reco mmend the use of downward flow systems (suction). Severe roof damage can result from any block age of air passages. Running fans during high humidity/cold weather conditions can cause air exhaust or intake ports to freeze.
2. Decals
HIGH VOLTAGE.
Will cause serious injury or death.
Lockout power before servicing.
DC-1224
DC-1225
DC-1227
DC-GBC-1A
DC-1224
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!
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.
Failure to heed these
warnings will result in
serious injury or death.
DC-GBC-1A
WARNING
PNEG-634 2000 Top Dry Fan/Heater 9
Flame and pressure beyond door can cause serious injury. Do not operate with service door removed. Keep head and hands clear.
DC-1227
WARNING
Stay clear of rotating blade. Blade could start automatically. Can cause serious injury. Disconnect power before servicing.
DC-1225

3. Installation

Fan/Heater Mounting
1. Inspect the fan platform for proper installation per instructions in the Top Dry erection manual.
2. Raise the Top Dry Fan/Heater units to the platform. Use the Table below to determine the height of the platform from the base of the Top Dry unit.
3. Mount the Top Dry Fan/Heater units to the bin entrance sheets. Fan legs should set on the platform.
Top Dry Bin Eave Height
# of Rings Eave Height
5 18'-5" 622'-1" 7 25'-9" 829'-5"
9 33'-1" 10 36'-9" 11 40'-5"
Control Box Mounting
1. Mount control boxes at eye level, regardless of whether using the manual control center of the econo control center. Makesure to have the control boxes mounted so that the fan and heater unit(s) are in view.
2. Keep in mind that wire will be used to interconnect the control center with the fan and heater unit(s).
3. Use the hole pattern in Figure 3C on Page 11 to drill holes for mounting the control box.
Figure 3A 2 Fan Top Dry Configuration
Figure 3B Control Box Mounted on Bin
3. Installation
Figure 3C Illustration of the bolt pattern for the manual
and econo control center.
PNEG-634 2000 Top Dry Fan/Heater 11
3. Installation
Grain Temperature Sensor Installation
1. Remove the two (2) wires attached to the grain temperature sensor connected to terminal #22 and terminal #23 in the fan control box.
2. Mount the grain temperature sensor bracket on an outside leveling band post. (See Figure 3E
on Page 13.)
3. Mount the brackets with bin bolts so that the sensor is 17-1/2" above the floor sheet rib.
4. Wire tie the cord so that it feeds up the leveling band post and across the top leveling band.
5. Route the cord through the space between the roof and the top sidewall sheet.
6. Route the cord back into the fan control box.
7. Install the two (2) wires from the cord into terminal #22 and terminal #23. (See Figure 3F on Page 14.)
Figure 3D Grain Temperature Sensor Bracket Mounted on Leveling Band Post
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