GSI PNEG-696 User Manual
2003 Series 2000
Autoflow Operation
Software Version 2.15
PNEG-696
PNEG-696
Series 2000 Autoflow Operation
Roof Damage Warning and Disclaimer.............................................................................4
Safety.............................................................................................................................5
Safety Precautions........................................................................................................6
Safety Sign-Off Sheet...................................................................................................7
Electrical Power Supply................................................................................................8
Electronic Monitoring Control System..............................................................................9
Dryer Control Panel..............................................................................................10
Set-Up Standard...................................................................................................14
Set-Up Extended...................................................................................................15
Fill System Control Box..............................................................................................18
Error Messages.............................................................................................................20
Pre-Season Checks......................................................................................................24
Top Dry Autoflow Theory of Operation.....................................................................27
Start Up Procedure......................................................................................................29
TopDry Autoflow Drying Rates for Shelled Corn......................................................32
TopDry Batch Drying Rates for Shelled Corn............................................................33
Warranty.....................................................................................................................34
TABLE OF CONTENTS
3
SAFETY
Series 2000 Autoflow Operation
Roof Damage Warning and Disclaimer
GSI 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. GSI DOES NOT RECOMMEND THE
USE OF DOWNWARD FLOW SYSTEMS (SUCTION). SEVERE ROOF DAMAGE CAN RESULT
FROM ANY BLOCKAGE OF AIR PASSAGES.
RUNNING FANS DURING HIGH HUMIDITY/
COLD WEATHER CONDITIONS CAN CAUSE AIR
EXHAUST OR INTAKE PORTS TO FREEZE.
Fan/Heater Installation & Operating Instructions
Thank you for choosing a Top Dry Series Autoflow.
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 single phase 230
volt, or three phase 208, 220, 380, 460 or 575 volt
electrical power.
The principal concern of the GSI Group, Inc.
("GSI") is your safety and the safety of others asso-
The symbol shown is used to call your
attention to instructions concerning
your personal safety. Watch for this
symbol; it points out important safety
precautions. It means "ATTENTION",
"WARNING", "CAUTION", and
"DANGER". Read the message and
be cautious to the possibility of personal injury or death.
ciated with grain handling equipment. This manual
is written to help you understand safe operating
procedures, and some of the problems that may be
en-countered by the operator or 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 who are in the fan area.
Avoid any alterations to the equipment. Such alterations may produce a very dangerous situation,
where serious injury or death may occur.
Safety Alert Symbol
WARNING! BE ALERT!
Personnel operating or working
around electric fans 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.
4
Series 2000 Autoflow Operation
Grain Systems, Inc. recommends contacting your local
power company, and having a
representative survey your installation so the wiring is compatible
with their system, and adequate
power is supplied to your 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 bottom right decal should be present
on the inside bin door cover of
the two ring door, 24" porthole
door cover and the roof manway
cover.
If a decal is damaged or is
missing contact:
Grain Systems, Inc.
1004 E. Illinois St.
Assumption, IL 62510
217-226-4421
A free replacement will be sent to
you.
SAFETY
5
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.
Series 2000 Autoflow Operation
Use Caution in the
Operation of this
Equipment
The design and manufacture of this
dryer is directed toward operator
safety. However, the very nature of
a grain dryer having a gas burner,
high voltage electrical equipment
and high speed rotating parts, does
present a hazard to personnel, which
can not be completely safeguarded
against, without interfering with efficient operation and reasonable access to 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.
7.
Use CAUTION in working around high speed fans, gas burners, augers
and auxiliary conveyors which START AUTOMATICALLY.
8.
Do not operate in any area where combustible material will be drawn into
the fan.
9.
Before attempting to remove and reinstall any propellor, 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 all tines when handling, assembling, installing and operation of the product and/or components.
Guards are removed for illustration purpose only. All guardsmust be in
place before/during operation.
KEEP THE DRYER CLEAN
DO NOT ALLOW FINE
MATERIAL TO ACCUMULATE
IN THE PLENUM CHAMBER
OR SURROUNDING THE
OUTSIDE OF THE DRYER
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 operation of the unit for
any developing problems or unsafe
conditions.
Take special note of the safety precautions listed above before attempting to operate the dryer.
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Series 2000 Autoflow Operation
SAFETY SIGN-OFF SHEET
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Date
Employer’s Signature
Employee
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7
ELECTRICAL POWER SUPPLY
Power Supply
An adequate power supply and proper wiring are important factors for maximum performance and long life of
the dryer. Electrical service must be adequate enough to
prevent low voltage damage to motors and control circuits (see Electrical Load Information).
Transformer and Wiring Voltage Drop
It is necessary to know the distance from the unit to the
available transformer, and the horsepower of your fan
unit. Advise the service representative of your local power
supplier that an additional load will be placed on the line.
Each fan motor should be wired through a fused or circuit breaker disconnect switch. Check on KVA rating of
transformers, considering total horsepower load. The
power supply wiring, main switch equipment and transformers must provide adequate motor starting and operating voltage. Voltage drop during motor starting should
not exceed 14% of normal voltage, and after motor is
running at full speed it should be within 8% of normal
voltage. Check Electrical Load Information for HP ratings and maximum amp loads to properly size wire and
fusing elements. Standard electrical safety practices and
codes should be used. (Refer to National Electrical Code
Standard Handbook by National Fire Protection Association).
Machine to Earth Grounding
It is very important that a
Rod
be installed at the fan. This is true even if there is
a ground at the pole 15 feet away. Place the ground
rod that comes standard, within 8 feet of the dryer
and attach it to the dryer control panel with at least a
#6 solid, bare, copper ground wire and the clamp provided. The grounding rod located at the power pole
will not provide adequate grounding for the dryer. The
proper grounding will provide additional safety in case
of any short and will ensure long life of all circuit
Machine To Earth Ground
Series 2000 Autoflow Operation
boards, and the ignition system. The ground rod must
be in accordance with local requirements.
Proper Installation of Ground Rod
It is not recommended that the rod be driven into dry
ground.
Follow these instructions for proper installation:
1.
Dig a hole large enough to hold 1 to 2 gallons of
water.
2.
Fill hole with water.
3.
Insert rod through water and jab it into the ground.
4.
Continue jabbing the rod up and
ter will work its way down the hole, making
it possible to work the rod completely into
the ground. This method of installing the
rod gives a good conductive bond with the sur
rounding soil.
5.
Connect the bare, copper
rod with the proper
Figure 8.
6.
Connect the bare copper ground wire to the fan
control boxes with a grounding lug.
7.
Ground wire must not have any
splices.
ground rod clamp. See
down. The wa
ground
wire to the
breaks or
Dig a hole large
enough to hold 1
or 2 gallons of
water. Work
the ground rod
into the earth
until it is com-
pletely in the
ground.
8
Series 2000 Autoflow Operation
Electronic Monitoring Control System
CONTROL PANEL
9
CONTROL PANEL
Series 2000 Autoflow Operation
Dryer Control Panel Featuring the
Electronic Monitoring Control System
The control panel provides easy access to gauges and
controls, and the illuminated switches provide a quick
reference for every operating function. The patent
pending Electronic Monitoring Control System is a
computerized control system that gives instant information regarding dryer operation.
Moisture Control Switch
This switch determines if the grain temperature
setpoint is used in the operation of the dryer. When
placed in the “on” position the dryer will not enter the
dump cycle until the grain temperature has reached the
grain temperature setpoint and the dry timer has
reached zero. When placed in the “on” position the
moisture control switch lights up when the grain
temperature is below the grain temperature setpoint.
When placed in the “off” position the dryer ignores the
grain temperature and operates strictly off of the dry
timer. When placed in the “off” position the moisture
control switch does not light up.
the “on” position the aeration fan comes on when the
dryer is running.
If the Aeration Fan Bypass is enabled in the Set-up, the
aeration fan remains running when the aeration fan
switch on the dryer control panel is placed in the “on”
position. With the aeration fan switch placed in the
“auto” position the aeration fan will stop any time the
dryer stops.
Load Auger Switch
This switch controls the operation of the fill system(s)
that load grain into the drying chamber. The switch
lights up when the fill system(s) are running. When
placed in the “auto” position the fill system(s) start and
stop automatically depending on the level of grain
relative to the drying chamber high level rotary switch.
When operating in the Autobatch mode the fill
system(s) will shut off 2/3 of the way through the dry
cycle even if grain has not reached the drying chamber
high level rotary switch. When placed in the “off”
position the fill system(s) will not run. When placed in
the “on” position the fill system(s) work the same as in
Auto, except the Out of Grain Timer is ignored.
Control Power Switch
The power to the Electronic Monitoring Control
System is turned on or off with the control power
switch. The switch lights up when placed in the “on”
position. If the switch is placed in the “on” position
and the light does not light up make sure that the
emergency stop switches located on the Autoflow
control box, and Fill System control box are pulled out.
Aeration Fan Switch
This switch controls the operation of the aeration fan
located at the bottom of the bin. The switch lights up
when the aeration fan comes on. When placed in the
“auto” position the aeration fan starts and stops with
the main drying fans. When placed in the “off”
position the aeration fan will not run. When placed in
Fan Switch
This switch controls the operation of the main drying
fan(s). The switch lights up when the airswitch located
in the sidewall next to the master drying fan senses an
increase in static pressure and closes. In the Autoflow
mode, when placed in the “auto” position the main
drying fan(s) start when grain reaches the drying
chamber low level rotary switch and do not stop until
the dryer shuts down or is stopped manually by pressing the stop switch. In the Autobatch mode the main
drying fan(s) shut off automatically in the dump cycle.
When placed in the “off’ position the main drying
fan(s) will not run. When placed in the “on” position
the main drying fan(s) come on and stay on when the
dryer is running.
10
Series 2000 Autoflow Operation
Heater Switch
CONTROL PANEL
This switch controls the operation of the burner(s).
The switch lights up when the burner is on. When
the burner is on small lights above and below the
heater switch indicate if the burner(s) are in high
fire or low fire. In the Autoflow mode, when
placed in the “auto” position, the burner(s) fire
when grain reaches the drying chamber low level
rotary switch and do not stop until the dryer shuts
down or is stopped manually by pressing the stop
switch. In the Autobatch mode the burner(s) shut
off automatically in the cool and dump cycle.
When placed in the “off” position the burner(s)
will not fire. When placed in the “on” position the
burner(s) fire anytime the main drying fan(s) are
running.
Dump Switch
This switch controls the operation of the linear
actuator housed in the actuator control box. The
switch lights up when the linear actuator is moving. When placed in the “manual close position”
the linear actuator in the actuator control box
retracts- raising the dump chutes. When placed in
the “auto” position the linear actuator extends at
the beginning of the dump cycle- lowering the
dump chutes, and retracts at the end of the dump
cycle- raising the dump chutes. When placed in
the “manual open” position the linear actuator extendslowering the dump chutes.
Dry And Hold Switch
When placed in the “on” position the grain in the
drying chamber will not be dumped into the storage
chamber at the end of the dry cycle, and the dryer will
stop and cool for as long as the cool timer is set. If no
cooling is desired set to 0. This switch can be used to
hold the last batch of grain in the drying chamber and
stop the dryer. When placed in the “off” position the
dryer will operate normally. The switch lights up when
placed in the “on” position.
Dryer Power Start Switch
This switch starts and operates the dryer based on
switch settings. The switch lights up when the dryer is
running. The dump switch is disabled after this switch
has been pushed.
Dryer Power Stop Switch
This switch stops all dryer functions. If an automatic
dryer shutdown occurs, first determine and correct the
cause of the shutdown. Then, press the dryer power
stop switch to reset the dryer before starting.
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