GSI PNEG-728 User Manual

Autoflow Operation

PNEG-728

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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

SAFETY

Autoflow Operation

Roof Damage Warning and Disclaimer

GSI DOES NOT WARRANT ANY ROOF DAMAGE

CAUSED BY EXCESSIVE VACUUM OR INTER-

NAL 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 (SUC-

TION). 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 ser-

vice for many years.

This manual describes the installation for all

standard production Top Dry single fan, multi-fan

and Heater Control units. Different models are avail-

able 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 per-

sonal injury or death.

ciated with grain handling equipment. This manual

is written to help you understand safe operating pro-

cedures and some of the problems that may be en-

countered by the operator or other personnel.

As owner and/or operator, it is your responsi-

bility to know what requirements, hazards and pre-

cautions exist, and to inform all personnel associ-

ated with the equipment or who are in the fan area.

Avoid any alterations to the equipment. Such al-

terations 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.

Autoflow Operation

The GSI Group Inc. recom-

mends contacting your local

power company, and having a

representative survey your instal-

lation 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 ro-

tating blade, fire warning decals

and voltage danger decal must be

displayed on the fan can. The bot-

tom 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:

The GSI Group Inc.

1004 E. Illinois St.

Assumption, IL 62510

217-226-4421

A free replacement will be sent to

you.

SAFETY

DECAL PLACEMENT

Autoflow Operation

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 de-

tected, 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 maxi-

mum recommended drying temperature.

6. Keep the dryer clean. Do not allow fine material to accumulate in the

plenum or drying chamber.

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

cannot be completely safeguarded

against without interfering with ef-

ficient operation and reasonable ac-

cess to components.

Use extreme caution in working

around high-speed fans, gas-fired

heaters, augers and auxiliary con-

veyors, which may start without

warning when the dryer is operat-

ing 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 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 all times when handling, assem-

bling, 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.

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 opera-

tion of automatic equipment de-

pends, to a great degree, upon the

owner. For a safe and dependable

drying system, follow the recom-

mendations within this manual, and

make it a practice to regularly in-

spect the operation of the unit for

any developing problems or unsafe

conditions.

Take special note of the safety pre-

cautions listed above before at-

tempting to operate the dryer.

SAFETY SIGN-OFF SHEET

Autoflow Operation

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Autoflow Operation

Power Supply

ELECTRICAL POWER SUPPLY

An adequate power supply and proper wiring are impor-

tant 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 cir-

cuits (see Electrical Load Information). In 220V 1-phase

and 220V 3-phase systems, a separate neutral wire is

required for the 120V heater circuit, and should be

connected to terminal #1 in the master heater. Do not

run in conduit with motor power lines.

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 fuse or circuit

breaker disconnect switch. Check on KVA rating of trans-

formers, considering total horsepower load. The power

supply wiring, main switch equipment and transformers

must provide adequate motor starting and operating volt-

age. Voltage drop during motor starting should not ex-

ceed 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 Stan-

dard Handbook by National Fire Protection Association).

Machine to Earth Grounding

It is very important that a Machine To Earth Ground

Rod be installed at the fan. This is true even if there is

a ground at the pole 15 feet (4.572 meters) away. Place

the ground rod that comes standard, within 8 feet

(2.438 meters) 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 boards, and the ignition

system. The ground rod must be in accordance with

local requirements.

Dave, any ideas what to put here,if anything?

CONTROL SYSTEM

Electronic Monitoring Control System

Autoflow Operation

CONTROL SYSTEM

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 Thermostat

This electronic thermostat controls the moisture

level of discharged grain by sensing grain column

temperature using the four (4) RTD temperature

sensors located in the drying chamber. The moisture

control thermostat indicates the current grain

temperature in the drying chamber with LEDs. The

grain temperature setpoint is set on the moisture

control thermostat. In the Autoflow mode, when the

grain temperature reaches the grain temperature

setpoint, and the dry timer has reached zero, the

dryer will dump the third driest portion of grain

from the drying chamber into the storage chamber.

In the Autobatch mode the dryer will dump all of the

grain into the storage chamber.

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 is pulled out.

24-Volt Power Switch

This switch turns the power on or off to the actuator

control box. 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 switch located on the

actuator control box is pulled out (1997 model only).

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 the on position, the aeration fan comes on when

the dryer is running.

Load Auger Switch

Moisture Control Switch

This switch turns the power on or off to the moisture

control thermostat. When placed in the on

position, the dryer will not enter the dump cycle

until the grain temperature has reached the grain

temperature setpoint on the moisture control thermo-

stat 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 set point on the moisture

control thermostat. When placed in the off

position, the dryer ignores the grain temperature and

operates strictly off the dry timer. When placed in

the off position, the moisture control switch does

not light up.

Control Power Switch

The power to the Electronic Monitoring Control

System is turned on or off with the control power

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

(two-thirds) 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) come

on and stay on when the dryer is running.

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

CONTROL SYSTEM

Dryer Control Panel, continued

Autoflow Operation

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.

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 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.

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 mov-

ing. 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

extends, lowering the dump chutes. This switch is

disabled when the dryer is running. The dryer

must be stopped to manually dump.

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. 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.

Heater Switch

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.

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 auto-

matic dryer shutdown occurs, first determine and

correct the cause of the shutdown. Press the dryer

power stop switch to reset the dryer before starting.

Autoflow Operation

CONTROL PANEL

CONTROL SYSTEM

Electronic Monitoring Control System

Autoflow Operation

CONTROL SYSTEM

Electronic Monitoring

Control System

The Electronic Monitoring Control System

controls all timing functions and safety circuit

checks. It is designed to simplify dryer operation

by providing printed messages and warnings on its

liquid crystal display (LCD).

Turning On The Electronic Monitoring

Control System

Turn the control power switch to the on

position. The monitor will display a copyright

message, software version number, total running

time in hours and minutes and the model number,

and the serial number and current time and date.

When the serial number and current time and date

are displayed, press the reset button to activate the

controller and enter the main drying screen.

Setting The Dry, Cool And Unload Timers

These switches are used to set the dry, cool

and dump cycle times. The current settings on

these timers are displayed directly above their timer

button. To change the setting of these timers do the

following:

1) Press the dry, cool or unload timer

button.

2) Press the modify button.

3) Press the increase or decrease button to

adjust the settings.

4) Press the enter button.

5) To enter the new value into memory

immediately, press the reset button.

During operation, the remaining time on

each timer is displayed on the screen. If the power

goes out or the dryer is stopped, these times are

saved by the controller. When the dryer is restarted,

the timers will continue timing down. The timers

will return to their initial settings by pressing the

reset button. The cool timer is not used in an

Autoflow system.

Setting The Aux. 1 Timer

The value set on the aux. 1 timer acts as a

buffer to allow grain to fall away from the drying

chamber low level rotary switch after the drying

fans start without giving an error. When grain

reaches the drying chamber low level rotary

switch, the drying cycle starts (if the fan switch is

placed in the auto or on position) and the aux.

1 timer begins to time down. If grain falls away

from the drying chamber low level rotary switch

before the time on the aux 1 timer reaches zero, no

error is given and the dryer continues in the drying

cycle. If grain falls away from the drying chamber

low level rotary switch after the aux. 1 timer

reaches zero, a drying chamber no grain error is

given and the dryer shuts down. The aux. 1 timer

should be set long enough so that the fill system(s)

have sufficient time to make up the grain that falls

away from the drying chamber low level rotary

switch when the fan(s) and heater(s) start; but,

should not be set too long. If the linear actuator

fails to retract, the dump chutes and grain runs

directly from the drying chamber to the storage

chamber without being dried, then the grain would

fall away from the drying chamber low level

rotary switch and a drying chamber no grain error

would be given. If the aux. 1 timer is set too long

and the linear actuator failed to retract, an unac-

ceptable amount of wet grain could flow from the

drying chamber to the storage chamber before a

drying chamber no grain error is given and the

dryer shuts down. The aux. 1 timer is set using

the same procedure as the dry and unload timers,

but the reset button does not need to be pressed to

enter the new values into memory immediately.

Setting the Out of Grain Timer

The value set on the out of grain timer is

the amount of time that grain has to reach the

drying chamber low level rotary switch when the

dryer is refilling after the dump cycle in an

Autobatch system. When the dump cycle is

complete, the out of grain timer begins to count

down. If grain does not reach the drying chamber

low level switch before the out of grain timer

reaches zero, the dryer will give an out of grain

error and shut down. The out of grain timer is not

used in an Autoflow system.

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GSI PNEG-728 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual