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GSi 2000 Series Installation Instructions Manual

Autoflow fan/heater and control
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Series 2000 Autoflow
Fan/Heater and Control
Installation Instructions
Installation Manual
PNEG-900
Date: 07-29-11
PNEG-900

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  • Page 1 Series 2000 Autoflow Fan/Heater and Control Installation Instructions Installation Manual PNEG-900 Date: 07-29-11 PNEG-900...
  • Page 2 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. PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 3: Table Of Contents

    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 ......................

  • Page 4: Chapter 1 Safety

    1. Safety 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.

  • Page 5: Series 2000 Autoflow Installation And Operating Instructions

    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.
  • Page 6 1. Safety 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 without interfering with the efficient operation of the dryer and reasonable access to its components.

  • Page 7: Safety Sign-Off Sheet

    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.

  • Page 8: Chapter 2 Decals

    2. Decals 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.
  • Page 9 2. Decals Rotating flighting will Flowing material will Crusted material will kill or dismember. trap and suffocate. collapse and suffocate. Keep clear of all augers. DO NOT ENTER this bin! HIGH VOLTAGE. If you must enter the bin: 1. Shut off and lock out all power. 2.

  • Page 10: Chapter 3 Installation

    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.
  • Page 11 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.

  • Page 12: Series 2000 Autoflow Control Box Bolt Pattern

    3. Installation Series 2000 Autoflow Control Box Bolt Pattern Figure 3C Illustration of the bolt pattern for the autoflow control box. PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 13: Control Box Mounting

    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.

  • Page 14: Fill System Control Box Bolt Pattern

    3. Installation Fill System Control Box Bolt Pattern Figure 3E Illustration of the bolt pattern for the fill system control box. PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...
  • Page 15 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.
  • Page 16 3. Installation Actuator Control Box Mounting (Continued) Figure 3G Bolt Pattern to Drill Holes for the Actuator Control Box PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 17: Multi-Grain Temperature Sensor

    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.

  • Page 18: Grain Temperature Sensor Mounted To Leveling Band Post

    3. Installation Grain Temperature Sensor Mounted to Leveling Band Post Figure 3I Figure 3J Illustration of grain temperature sensor mounted on outside leveling band post. PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 19: Close-Up Detail Of Grain Temperature Sensor Wiring

    3. Installation Close-Up Detail of Grain Temperature Sensor Wiring Figure 3K PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 20: Plenum Temperature Sensor

    3. Installation Plenum Temperature Sensor The plenum temperature sensor is the small grey PVC junction box attached by a cord to the fan/heater control box on the master fan/heater unit. 1. On either side of the fan/heater, drill one 3/4" hole even with the fan/heater unit in a valley on the bin sidewall.

  • Page 21: Plenum High-Limit Installation

    3. Installation Plenum High-Limit Installation Figure 3M 30' Top Dry Layout Plenum High-Limit PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 22: Top Dry Plenum High-Limit Installation

    3. Installation Top Dry Plenum High-Limit Installation 1. Assemble two (2) pieces of conduit together with coupler. 2. Mount conduit clamps to conduit assembly. 3. Locate conduit assembly on the bottom of a rafter at least 2' to one side of the fan entrance. Do not install between 2 fan entrances.

  • Page 23: Wet Supply Rotary Switch

    3. Installation Wet Supply Rotary Switch 1. Drill a 2" diameter hole through the hopper bottom. If a flat bottom bin is being used for a wet storage tank the Wet Supply Rotary switch would be mounted 45° up the sidewall from the center of the bin. Example: If the wet storage bin is 18' in diameter then the Wet Supply Rotary switch would be mounted 9' up the sidewall.
  • Page 24 3. Installation Figure 3P PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 25: Storage Chamber High-Limit Rotary Switch Installation

    3. Installation Storage Chamber High-Limit Rotary Switch Installation 1. Drill a 2" diameter hole through the sidewall 3' below the fan/heater. 2. If the bin is 2.66" corrugation, the hole should be centered on an outside hill. 3. If the bin is 4.00" corrugation, the hole should be centered on an outside valley. 4.
  • Page 26 3. Installation Figure 3R PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 27: Drying Chamber Rotary Switches Mounted In Bin Roof

    3. Installation Drying Chamber Rotary Switches Mounted in Bin Roof The three (3) Drying Chamber rotary switches are used by the Series 2000 Autoflow to monitor the location of grain in the drying chamber. The rotary switch with the shortest shaft extension is the Drying Chamber Overflow Rotary switch.

  • Page 28: Drying Chamber Low-Level Rotary Switch Installation

    3. Installation Drying Chamber Low-Level Rotary Switch Installation 1. Drill a 2" diameter hole through the roof panel at the location shown in Figure 3T. See component placement on Page 11 for proper placement in relation to fill auger. 2. Use the mounting plate as a pattern and drill four (4) 3/8" holes through the roof panel at the switch location so the plate can be bolted to the roof.
  • Page 29 3. Installation Figure 3U PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 30: Drying Chamber High-Level Rotary Switch Installation

    3. Installation Drying Chamber High-Level Rotary Switch Installation 1. Drill a 2" diameter hole through the roof panel at the location shown in Figure 3T on Page See component placement on Page 11 for proper placement in relation to fill auger. 2.

  • Page 31: Drying Chamber Overflow Rotary Switch Installation

    3. Installation Drying Chamber Overflow Rotary Switch Installation 1. Drill a 2" diameter hole through the roof panel at the location shown in Figure 3T on Page See component placement on Page 11 for proper placement in relation to fill auger. 2.

  • Page 32: Liquid Propane (Lp)

    3. Installation Liquid Propane (LP) Top Dry dryers have internal vaporizers and are designed to operate on liquid draw from the supply tank. Avoid using propane supply tanks that have been used for vapor draw for long periods of time. When using liquid draw systems, any moisture that may be present in tanks or lines may freeze when the system is used in cold weather.

  • Page 33: Natural Gas (Ng)

    3. Installation Natural Gas (NG) This dryer is designed to operate on natural gas. Natural gas units have a larger orifice to accommodate lower pressures sometimes found with natural gas and do not have vaporizer coils like liquid propane units. A regulated pressure of 10 PSI minimum, 30 PSI maximum must be provided at the field connection point on the fan/heater unit, with gas available in sufficient volume to maintain the operating pressure.

  • Page 34: Chapter 4 Electrical Power Supply

    4. Electrical Power Supply Conduit Runs Control Wires Run #1 Autoflow control box to master fan/heater control box. Five (5) - Control wires 16 gauge minimum. (NOTE: A shielded two (2) conductor 16 gauge cable should be used for the network connections.) Run #2 Autoflow control box to actuator control box.

  • Page 35: Grounding

    4. Electrical Power Supply Grounding All control boxes should be properly grounded with a ground lug mounted in each control box. Power Supply An adequate power supply and proper wiring are important factors to achieve maximum performance and long life of the dryer. Electrical service must be adequate enough to prevent low voltage damage to motors and control circuits.

  • Page 36: Proper Installation Of Ground Rod

    4. Electrical Power Supply Proper Installation of Ground Rod The ground rod should not 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.
  • Page 37 4. Electrical Power Supply Figure 4B The Top Dry and Ground Rod Attachment Illustration PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 38: Power/Motor Wiring

    4. Electrical Power Supply Power/Motor Wiring Figure 4C details the configuration for correct main power installation. Use the diagram in conjunction with the electrical load information and wire size information provided. The diagram details the correct main power installation for 220V 1 PH, 230V 3 PH, 460V 3 PH, 575V 3 PH and 380V 3 PH 50 Hz power supplies.

  • Page 39: Electrical Load Information

    4. Electrical Power Supply Electrical Load Information Chart below provide information for the electrician wiring the grain dryer and are a reference guide for parts. It is recommended that you contact your local power company and have a representatives survey the installation to see that the wiring is compatible with their system and that adequate power is supplied to the unit.
  • Page 40 4. Electrical Power Supply Figure 4D PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 41: Autoflow To Master Fan/Heater Unit Interconnect

    NOTE: A shielded 16 gauge cable is recommended for use on the network connection. The network wires for this configuration are attached to terminal #4 and terminal #5. Ground each end of the shielded cable to the housing. A shielded 16 gauge 2 wire cable can be purchased from GSI. Part #WR-16/2S.

  • Page 42: Autoflow To Actuator Interconnect

    4. Electrical Power Supply Autoflow to Actuator Interconnect The actuator control box houses the 24V DC linear actuator, two (2) 12V DC batteries and a 24V DC battery charger. The linear actuator raises and lowers the dump chutes to unload grain automatically from the drying chamber to the storage chamber.

  • Page 43: Autoflow To Wet Supply Rotary Switch Interconnect

    4. Electrical Power Supply Autoflow to Wet Supply Rotary Switch Interconnect The 110V AC rotary switch located in the wet storage tank is used to inform the computer on the availability of wet grain. The Wet Supply Rotary switch use 110V AC to power the motor and 12V DC+ to switch a signal back to the computer.

  • Page 44: Autoflow To Storage Chamber Rotary Switch Interconnect

    4. Electrical Power Supply Autoflow to Storage Chamber Rotary Switch Interconnect The 110V AC rotary switch located in the storage tank is used to inform the computer on the availability of wet grain. The Storage Chamber Rotary switch is mounted 3' below the fan/heater unit(s). The Storage Chamber Rotary switch use 110V AC to power the motor and 12V DC+ to switch a signal back to the computer.
  • Page 45 4. Electrical Power Supply Figure 4I PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 46: Autoflow To Fill System Control Box Interconnect

    4. Electrical Power Supply Autoflow to Fill System Control Box Interconnect The fill system control box houses the starter(s) for the fill system(s) that load grain into the Top Dry Autoflow unit and for the aeration fan. DO NOT run the control wires for the fill system control box in the same conduit used for the power wires for the fill system and aeration fan motors.

  • Page 47: Autoflow To Ground Interconnect

    4. Electrical Power Supply Autoflow to Ground Interconnect Figure 4K PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 48: Master To Slave Interconnect

    #3 and terminal #4 in the slave unit. Ground each end of the shielded cable to the housing. A shielded 16 gauge 2 wire cable can be purchased from GSI. Part #WR-16/2S. Slave #1 Fan and Heater Dip Switch Setting: #2 - “OFF”/All Others - “ON”...

  • Page 49: Slave To Slave Interconnect

    #3 and terminal #4 in slave #2. Ground each end of the shielded cable to the housing. A shielded 16 gauge 2 wire cable can be purchased from GSI. Part #WR-16/2S Slave #2 Fan and Heater Dip Switch Setting: #1 and #2 - “OFF”/ All Others - “ON”...

  • Page 50: Battery Hook-Up

    Figure 4N to guide installation. 12 Volt batteries are not supplied by GSI. Use 12V lawn and garden type mount batteries on battery shelves in actuator control box 24 volt charger should hook-up to positive and negative as shown. Check polarity.
  • Page 51 4. Electrical Power Supply 6. The linear actuator should extend down 16". 7. Place the Dump switch in the “AUTO” position and press the Stop switch. 8. The linear actuator should retract and stop. 9. Place the Control Power switch in the “OFF” position and push the Emergency Stop switch in on the Autoflow and actuator control boxes.
  • Page 52 NOTES PNEG-900 Series 2000 Autoflow Fan/Heater and Control Installation Instructions...

  • Page 53: Chapter 5 Warranty

    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.
  • Page 54 Authorities having jurisdiction should be consulted before installations are made. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.com Copyright © 2011 by GSI Group Printed in the USA...

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