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GSi TopDry Autoflow 2000 Series Operation Manual

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TopDry Series 2000 Autoflow
Operation Manual
PNEG-696
Date: 09-27-20
PNEG-696

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Summary of Contents for GSi TopDry Autoflow 2000 Series

  • Page 1 TopDry Series 2000 Autoflow Operation Manual PNEG-696 Date: 09-27-20 PNEG-696...
  • Page 2 All information, illustrations, photos and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. PNEG-696 TopDry Series 2000 Autoflow...

  • Page 3: Table Of Contents

    Table of Contents Contents Chapter 1 Safety ..............................5 Cautionary Symbols Definitions ......................5 Fan/Heater Installation and Operating Instructions ................6 Safety Precautions ..........................7 Safety Sign-Off Sheet ........................... 8 Chapter 2 Safety Decals ............................9 Chapter 3 Electrical Power Supply ........................11 Power Supply ............................
  • Page 4 Table of Contents Chapter 7 Error Messages ..........................22 Burner 1 Loss Flame ........................... 22 Burner 2 Loss Flame ........................... 22 Fan 1 Vapor High-Limit ........................22 Fan 2 Vapor High-Limit ........................22 Fan 1 Housing High-Limit ........................22 Fan 2 Housing High-Limit ........................22 Plenum High-Limit ..........................

  • Page 5: Chapter 1 Safety

    1. Safety Cautionary Symbols Definitions Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we use the symbols that are defined below. This symbol indicates an imminently hazardous situation DANGER which, if not avoided, will result in serious injury or death.

  • Page 6: Fan/Heater Installation And Operating Instructions

    1. Safety Fan/Heater Installation and Operating Instructions Thank you for choosing a TopDry Series Autoflow. It is designed to give excellent performance and service for many years. This manual describes the installation for all standard production TopDry Series 2000 single fan, multi-fan and 2000 Series Heater Control units.

  • Page 7: Safety Precautions

    1. Safety 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.

  • Page 8: 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 9: Chapter 2 Safety Decals

    Safety decals should be read and understood by all people in and around the dryer area. If the following safety decals are not displayed on your dryer or if they are damaged, contact The GSI Group for replacement: GSI Decals 1004 E.
  • Page 10 Lockout power Failure to do so will result before servicing. in serious injury or death. DC-973 GSI Group 217-226-4421 DC-1224 DC-973 DC-1224 WARNING Stay clear of rotating blade. Blade could start automatically. Can cause serious injury.

  • Page 11: Chapter 3 Electrical Power Supply

    3. 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.

  • Page 12: Chapter 4 Control Panel

    4. Control Panel Electronic Monitoring Control System Figure 4A PNEG-696 TopDry Series 2000 Autoflow...

  • Page 13: Dryer Control Panel Featuring The Electronic Monitoring Control System

    4. Control Panel 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.

  • Page 14: Fan Switch

    4. Control Panel Fan Switch This switch controls the operation of the main drying fan(s). The switch illuminates when the Air switch located in the sidewall next to the master drying fan senses an increase in static pressure and closes. In the Autobatch mode, the main drying fan(s) shut off automatically in the dump cycle.

  • Page 15: Chapter 5 Control System

    5. 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). Electronic Monitoring Control System Figure 5A Turning On the Electronic Monitoring Control System Turn the Control Power switch to the “ON”...

  • Page 16: Setting The Dry, Cool And Unload Timers

    5. Control System 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.

  • Page 17: Set-Up: Standard

    5. Control System Fans Off Delay - The fans off delay allows the fan and heater unit(s) to be shut down during the dump cycle. This will prevent the drying floor from becoming excessively dirty when there is a large amount of foreign material present in the grain being dried.
  • Page 18 5. Control System Aeration Fan Bypass - Allows the aeration fan to remain running after the dryer has shut down. Use the increase and decrease buttons to toggle between enabled and disabled. When the aeration fan bypass is enabled, the aeration fan will remain running after the dryer has stopped if the Aeration switch ON the dryer front panel is placed in the “ON”...

  • Page 19: Plenum And Grain Temperature Settings, Screens Button Options

    5. Control System Plenum and Grain Temperature Settings, Screens Button Options Plenum The temperature that the burner cycles from high-fire to low-fire is set here. Use the increase and decrease to change the value. Press enter when done. Grain The grain temperature set-point is set here. Use the increase and decrease buttons to change the grain temperature set point.

  • Page 20: Chapter 6 Fill System Control Box

    6. Fill System Control Box Grain system inc, Assumption, IL 217-226-4421 AUTO AUTO AUTO Fill System Fill System Aeration fan WARNING! Fill system and aeration fans will not run when switches are placed in the “OFF” position. Figure 6A PNEG-696 TopDry Series 2000 Autoflow...

  • Page 21: Fill System #1

    6. Fill System Control Box Fill System Control Box The fill system control box houses the motor starters for fill system #1, fill system #2 and the aeration fan. Switches are located on the front of the fill system control box and an Emergency Stop switch is located on the side of the control box.

  • Page 22: Chapter 7 Error Messages

    7. Error Messages When the dryer shuts down the user can quickly determine what caused the shut down by viewing the display on the dryer control panel. The Electronic Monitoring Control System displays the error message and sounds a warning signal to alert the user. The displayed error conditions and their electrical cause are as follows: Burner 1 Loss Flame The flame sensor in burner number one has failed to detect flame.

  • Page 23: Plenum High-Limit

    7. Error Messages Plenum High-Limit An over temperature condition has occurred inside the dryer plenum. The plenum high-limit is set automatically on the high-low thermostat when the cycle set point is adjusted and resets automatically when cooled. The low-fire gas pressure needs to be lowered or the cycle set point on the high-low thermostat needs to be increased if the error is displayed frequently.

  • Page 24: Fill 1 Motor Overload

    7. Error Messages Fill 1 Motor Overload The thermal overload in the fill system control box for fill system number one has tripped, indicating an overcurrent condition. The overload must be reset manually. Fill 2 Motor Overload The thermal overload in the fill system control box for fill system number two (2) has tripped, indicating an overcurrent condition.

  • Page 25: Chapter 8 Pre-Season Checks

    8. Pre-Season Checks Before the dryer is filled, thoroughly inspect the unit and check the operation of the dryer as follows. When entering the bin take great caution. Never enter a bin where grain is present. Set Control Switches 1. Moisture Control Switch - “ON” 2.

  • Page 26: Linear Actuator

    8. Pre-Season Checks Linear Actuator Turn the Dump switch on the Autoflow control box to the “MANUAL OPEN” position. Use a tape measure to measure the stroke on the linear actuator. The stroke should be between 16" and 18". If the stroke on the actuator is not 16"...

  • Page 27: Fill System

    8. Pre-Season Checks Fill System Prepare the wet storage tank to deliver grain to the dryer. Make sure all personnel are away from any machinery that is controlled by the Autoflow. Place the Load Auger switch in the “AUTO” position. The fill system(s) should begin to load grain from the wet supply tank to the dryer.

  • Page 28: Chapter 9 Autoflow Theory

    9. Autoflow Theory TopDry Autoflow Theory of Operation Control Panel Switch Status 1. Control Power: “ON” 2. Moisture Control Thermostat: “ON” 3. Aeration Fan: “AUTO” 4. Load Auger: “AUTO” 5. Fan: “AUTO” 6. Heater: “AUTO” 7. Dump: “AUTO” 8. Dry and Hold: “OFF” Emergency Stop Switch Status 1.
  • Page 29 9. Autoflow Theory After the dump cycle the unit returns to the beginning of the dry cycle, the fill system(s) refill the drying chamber and the process begins again. If the dry timer reaches zero after the grain temperature reaches the grain temperature set point the unit does not enter temperature hold.

  • Page 30: Chapter 10 Start-Up Procedure

    10. Start-Up Procedure At the beginning of each harvest and before filling the dryer with grain make sure to inspect the dryer for rodent damage and system integrity. Enter the drying chamber and check each dump hopper. Remove any obstructions. Test operate the dryer using the pre-season checklist. There are two (2) fundamental things to control with the Autoflow TopDry (or any dryer).
  • Page 31 10. Start-Up Procedure 11. Press the reset button for timer changes to take effect immediately. 12. Set the grain temperature set point as follows: • 180° drying temperature = 100° grain temperature set point • 170° drying temperature = 103° grain temperature set point •...

  • Page 32: Normal Start-Up

    10. Start-Up Procedure Normal Start-Up When the dryer is started with grain in the drying chamber that has already been partially dried, the dryer can be started without making any adjustments to time or temperature; however, the moisture of the grain should be checked after the fourth dump.

  • Page 33: Chapter 11 Drying Rates

    11. Drying Rates TopDry Autoflow Series Drying Rates for Shelled Corn Autoflow Series 21' Dia. 1 Fan 24' Dia. 1 Fan 30' Dia. 1 Fan Moisture Fan and Plenum Minutes Minutes Minutes Content Heater Temperature Bu/Hr Between Bu/Hr Between Bu/Hr Between Unit(s) F°...
  • Page 34 11. Drying Rates TopDry Autoflow Series Drying Rates for Shelled Corn Autoflow Series 30' Dia. 2 Fan 36' Dia. 1 Fan 36' Dia. 2 Fan Moisture Fan and Plenum Minutes Minutes Minutes Content Heater Temperature Bu/Hr Between Bu/Hr Between Bu/Hr Between Unit(s) F°...

  • Page 35: Chapter 12 Autoflow Series Drying Rates

    12. Autoflow Series Drying Rates Shelled Corn (Metric Measurements) 6.40 m 7.32 m 9.14 m Autoflow Series 1 Fan 1 Fan 1 Fan Dia. Dia. Dia. Moisture Fan and Plenum Minutes Minutes Minutes Content Heater Temperature MT/Hr Between MT/Hr Between MT/Hr Between Unit(s)
  • Page 36 12. Autoflow Series Drying Rates Shelled Corn (Metric Measurements) 9.14 m 10.97 m 10.97 m Autoflow Series 2 Fan 1 Fan 2 Fan Dia. Dia. Dia. Moisture Fan and Plenum Minutes Minutes Minutes Content Heater Temperature MT / hr Between MT / hr Between MT / hr...

  • Page 37: Chapter 13 Warranty

    12 months from the date of shipment (or, if shipped by vessel, 14 months from the date of arrival at the port of discharge). If, in GSI’s sole judgment, a product is found to have a defect in materials and/or workmanship, GSI will, at its own option and expense, repair or replace the product or refund the purchase price.
  • Page 38 Authorities having jurisdiction should be consulted before installations are made. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.com GSI is a worldwide brand of AGCO Corporation. Copyright © 2015 by The GSI Group, LLC Printed in the USA CN-315236...

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