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PNEG-900
User Manual
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GSI PNEG-900 User Manual

PNEG-900
Series 2000 Autoflow Fan/Heater and Control Installation Instructions
Installation Manual
PNEG-900
Date: 02-07-13
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
Series 2000 Autoflow 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
Autoflow Control Box Mounting ........................................................................................................... 10
Series 2000 Autoflow Control Box Bolt Pattern ................................................................................... 12
Control Box Mounting .......................................................................................................................... 13
Fill System Control Box Bolt Pattern ................................................................................................... 14
Multi-Grain Temperature Sensor ............ ... ... .... ... ... ... .... ... .......................................... ... ... ... .... ... ......... 17
Grain Temperature Sensor Mounted to Leveling Band Post .............................................................. 18
Close-Up Detail of Grain Temperature Sensor Wiring ........................................................................ 19
Plenum Temperature Sensor .............................................................................................................. 20
Plenum High-Limit Installation ............................................................................................................. 21
Top Dry Plenum High-Limit Installation ............................................................................................... 22
Wet Supply Rotary Switch ................................................................................................................... 23
Storage Chamber High-Limit Rotary Switch Installation ..................................................................... 25
Drying Chamber Rotary Switches Mounted in Bin Roof ..................................................................... 27
Drying Chamber Low-Level Rotary Switch Installation ....................................................................... 28
Drying Chamber High-Level Rotary Switch Installation ...................................................................... 30
Drying Chamber Overflow Rotary Switch Installation ......................................................................... 31
Liquid Propane (LP) ........ .......................................... .... .......................................... ... ......................... 32
Natural Gas (NG) ................................................................................................................................ 33
Chapter 4 Electrical Power Supply .....................................................................................................................34
Conduit Runs ...................................................................................................................................... 34
Grounding ........................................................................................................................................... 35
Power Supply ...................................................................................................................................... 35
Transformer and Wiring Voltage Drop ................................................................................................ 35
Machine to Earth Grounding ............................................................................................................... 35
Proper Installation of Ground Rod ....................................................................................................... 36
Power/Motor Wiring ...................... .... ... ... ... ... ....................................................................................... 38
Electrical Load Information .................................................................................................................. 39
Autoflow to Master Fan/Heater Unit Interconnect ............................................................................... 41
Autoflow to Actuator Interconnect ....................................................................................................... 42
Autoflow to Wet Supply Rotary Switch Interconnect ........................................................................... 43
Autoflow to Storage Chamber Rotary Switch Interconnect ................................................................. 44
Autoflow to Drying Chamber Rotary Switches Interconnect ............................................................... 44
Autoflow to Fill System Control Box Interconnect ............................................................ ... .... ...........
Autoflow to Ground Interconnect ......................................................................................................... 47
Master to Slave Interconnect ................................. ... .... .......................................... ... ......................... 48
Slave to Slave Interconnect ................................................................................................................ 49
Battery Hook-Up .................................................................................................................................. 50
Dump Chute Cable Installation ........................................................................................................... 50
Chapter 5 Warranty ..............................................................................................................................................53
. 46
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructio ns 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
Series 2000 Autoflow Installation and Operating Instructions
Thank you for choosing a Top Dry Series 2000 Autoflow 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 Autoflow 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 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.
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.
Proper Use of Product
This product is intended for the use of drying small grains only. Any other use is a misuse of the product. This product has sharp edges. These sharp edges may cause serious injury. To avoid injury handle sharp
edges with caution and use proper protective clothing and equipment at all times. Guards are removed for illustration purposes only. All guard s must be in place before and during operation.
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 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-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 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
GSI Group, Inc. 217-226-4421
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-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 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
NOTE: Do not install this control panel near any transformers or any other device that will produce an
electro magnetic field.
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"
Autoflow Control Box Mounting
Figure 3A Autoflow Control Box Mounted on Bin
3. Installation
1. The Autoflow control box should be mounted at eye-level. Make sure to mount the Autoflow control box so that the fan/heater unit(s) are in view.
2. Keep in mind that wire will be used to interconnect the Autoflow control box with the fan/heater unit(s), fill system control box, actuator and all rotary switches.
3. Use the hole pattern in Figure 3C on Page 12 to drill holes for mounting the Autoflow control box.
Figure 3B Component Placement
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 11
3. Installation
Series 2000 Autoflow Control Box Bolt Pattern
Figure 3C Illustration of the bolt pattern for the autoflow control box.
3. Installation
Control Box Mounting
Fill System Control Box Mounting
1. The fill system control box should be mounted at eye-level. Make sure to install the fill system control box so that the fill system(s) and aeration fan are in view.
2. Keep in mind that wire will be used to interconnect the fill system control box with the Autoflow control box; and, that power wires will have to be run from the entrance panel to the fill system control box to power the fill system and aeration fan motors, which will also run from the fill system control box.
3. Use the pattern in Figure 3E on Page 14 to drill holes for the fill system control box.
Figure 3D Fill System Control Box Mounted to Bin
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 13
3. Installation
Fill System Control Box Bolt Pattern
Figure 3E Illustration of the bolt pattern for the fill system control box.
3. Installation
Actuator Control Box Mounting
1. Mark the third sidewall ring from the ground to indicate the cable path if dump chutes and cable are already installed.
2. Make sure that all dump chutes and chains are EVENLY adjusted so that when one chute is level the others are level as well.
3. Keep in mind that wire will be used to interconnect the actuator control box with the Autoflow control box; and, that a 110V power supply will need to run from the entrance panel to the actuator control box to power the 24V DC battery charger.
4. Use the pattern in Figure 3G on Page 16 to drill holes for the actuator control box.
5. If the horizontal seam bolts are within 1" horizontally of the hole pattern shown, existing holes may be used to attach the actuator.
6. Use four (4) 5/16" x 1-1/4" bin bolts and washers with bolt heads to the inside of the bin.
7. Do not attach the dump chute cable to the actuator at this time. The cable should not be installed until after the actuator unit is completely wired and tested.
Figure 3F Actuator Control Box Mounted to Bin
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 15
3. Installation
Actuator Control Box Mounting (Continued)
Figure 3G Bolt Pattern to Drill Holes for the Actuator Control Box
3. Installation
Multi-Grain Temperature Sensor
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 four (4) grain temperature sensor brackets evenly around the drying chamber on outside leveling band posts. (See Figure 3I on Page 18.)
3. Mount the brackets with bin bolts so that the sensor is 8-1/2" above the floor sheet rib for Auto drying mode and 10-1/2" above the floor sheet rib for Batch drying mode . For AUTO drying, the bottom hole in the mounting bracket should align with the third hole from the bottom of the leveling band post. For BATCH drying, the bottom hole in the mounting bracket should align with the fourth hole from the bottom of the leveling band post.
4. Wire tie the cords so they feed up the leveling band post and across the top leveling band.
5. Route the cords through the space between the roof and the top sidewall sheet. There should be enough on all temperature sensor brackets to exit the drying chamber at the same place.
6. Route the cords into the junction box after the junction box has been mounted to the bin.
7. Wire the four (4) temperature sensors as shown in Figure 3H and on Page 19.
Figure 3H Illustration of the grain temperature sensor interconnection.
PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions 17
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