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GSi TopDry Series Operator's Manual

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CE Compliant Top Dry
Series 2000 Autoflow
Operators Manual
PNEG-1820CE
Date: 01-20-14
PNEG-1820CE

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  • Page 1 CE Compliant Top Dry Series 2000 Autoflow Operators Manual PNEG-1820CE Date: 01-20-14 PNEG-1820CE...
  • Page 2 PNEG-1820CE CE Compliant Top Dry Series 2000 Autoflow...

  • Page 3: Table Of Contents

    Table of Contents Contents Chapter 1 Safety ..............................4 Safety Guidelines ..........................4 Fan/Heater Installation and Operating Instructions ................5 Safety Sign-Off Sheet ........................... 7 Chapter 2 Decals ..............................8 Chapter 3 Fuel and Electrical Specifications ....................11 Top Dry CE Heater Specifications ...................... 11 Chapter 4 Electrical Installation .........................12 Machine to Earth Connection ......................

  • 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: Fan/Heater Installation And Operating Instructions

    CE Compliance This dryer has been designed to comply with EU Directives. Compliance depends upon the dryer being constructed, installed and operated in accordance with GSI instructions. General Safety Before operating your Top Dry, please read and understand this manual.
  • Page 6 Sound levels around the fan and heater may exceed 80 dBa. Avoid working in this area and wear hearing defenders. FOR GUIDANCE OR ASSISTANCE ON ANY ISSUES RELATING TO THE SAFE USE OF THE TOP DRY CONTACT: GSI Group 1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421 Drying flammable grains and seeds.

  • 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 auger. This sign-off sheet is provided for your convenience and personal record keeping.

  • Page 8: Chapter 2 Decals

    Safety decals must be read and understood by all people in and around the top dry area. If any safety decals are not displayed on the top dry or if they are damaged, contact the GSI Group, Inc. for replacement: Decals 1004 E.
  • Page 9 2. Decals DC-2163 Background: White Colors: Black, ANSI Yellow and ANSI Blue Size: 3.940" x 1.970" GSI Group 217-226-4421 DC-2163 DC-2164 Automatic Machinery Automatické stroje a zařízení Automatikus Machinery Background: White автоматични машини Colors: Black, ANSI Yellow and ANSI Blue automatische machines Size: 3.940"...
  • Page 10 2. Decals DC-2166 GSI Group Inc. 217-226-4421 DC-2210 DC-2210 DC-2166 Background: White Background: White Colors: Black, ANSI Yellow, ANSI Blue and ANSI Red Colors: Black and ANSI Blue Size: 5.910" x 3.940" Size: 5.910" x 3.940" DC-2211 Background: White Colors: Black, ANSI Yellow and ANSI Blue Size: 3.940"...

  • Page 11: Chapter 3 Fuel And Electrical Specifications

    3. Fuel and Electrical Specifications Top Dry CE Heater Specifications Fuel Specifications Gross CV = 98.37 MJ/m Maximum Minimum Maximum Maximum Minimum Maximum Minimum Maximum Minimum Orifice Motor Burner Burner Static Static Heat Heat I.D. Pressure Pressure Flow mBar mBar 36"...

  • Page 12: Chapter 4 Electrical Installation

    4. Electrical Installation The electrical supply must be capable of the full demand from the dryer, including aeration fan, fill and empty equipment and start currents. All CE Top Dry fans are star delta starting. Refer to electrical specifications Table on Page 11 for minimum current demand per fan heater.

  • Page 13: Chapter 5 Fuel Installation

    5. Fuel Installation Fuel Supply The dryer requires a suitable fuel supply. Refer to fuel specifications Table on Page 11 for fuel flow requirements. Liquid LPG Dryers with internal vaporizers require LPG in liquid form. Vapor LPG Dryers without internal vaporizers require LPG in vapor form. LPG tanks must have adequate vaporizing capacity to supply the maximum fuel flow given in fuel specifications Table on Page...

  • Page 14: Chapter 6 Control Panel

    6. Control Panel Dryer Control Panel Figure 6A Moisture Control Switch Determines if the grain temperature set point is used in the operation of the dryer. When “ON” position, the grain will be dumped when it reaches the temperature set point and the dry timer has reached zero.
  • Page 15 6. Control Panel Load Auger Switch Controls the operation of the drying chamber fill system(s). Switch is lit when the fill system(s) are running. AUTO = Fill system(s) start and stop automatically depending level of grain in drying chamber. When operating in the Autobatch mode the fill system(s) will shut off 2/3 of the way through the dry cycle regardless of drying chamber level.

  • Page 16: Chapter 7 Control System

    7. Control System Electronic Monitoring Control System Figure 7A Electronic Monitoring Control System This controls all timing functions and safety circuits. It provides printed messages and warnings. Turn control power to “ON” to start the control. The control will enter the main drying screen. Setting the Dry, Cool and Unload Timers These set the dry, cool and dump cycle times.
  • Page 17 7. Control System Setting the Delays The following timers are set using the same procedure, but the Reset button does not need to be pressed to enter the new values into memory immediately. AUX. 1 DELAY - Not used. REFILL DELAY - Used only on batch units. This delays the start of drying to allow the drying chamber to fill.
  • Page 18 7. Control System Use the Increase and Decrease buttons to select the correct time or date. Press the Enter button to accept. LOW LEVEL TEST MODE - Use the Increase and Decrease buttons to enable or disable Drying Chamber Low Level switch monitoring. WET TANK TEST MODE - Use the Increase and Decrease buttons to enabled or disabled wet supply level switch monitoring.

  • Page 19: Chapter 8 Fill System Control Box

    HIGH VOLTAGE will not run when switches are Will cause serious injury or death. Lockout power before servicing. GSI Group 217-226-4421 placed in the “off” position. DC-1312 Figure 8A The fill system control box houses the motor starters for fill system #1, fill system #2 and the aeration fan.
  • Page 20 8. Fill System Control Box Flame probe Ignitor Figure 8B Ignitor and Flame Probe Assemblies PNEG-1820CE CE Compliant Top Dry Series 2000 Autoflow...
  • Page 21 8. Fill System Control Box Figure 8C LP Vaporizer Coil Adjustment Flame Probe, Ignitor and Burner Assemblies Parts List Ref # Description Flame Probe Assembly Network Boot 8 mm Silicone 90° Flame Sensor 6" Long Rod Flame Sensor Bracket Ignitor Assembly Dual Probe Ignitor Bracket Ignitor Air Deflector Angle Ignitor Half Clamp...

  • Page 22: Chapter 9 Error Messages And Valve Proving System

    9. Error Messages and Valve Proving System Error Messages Burner * Loss Flame The flame sensor in burner number * has failed to detect flame. Possible causes: Burner failed to light. 1. Check fuel supply and pressure. 2. Check spark. 3.
  • Page 23 9. Error Messages and Valve Proving System Drying Chamber Overflow The grain level in the drying chamber has reached the Drying Chamber Overflow Rotary switch. Grain will have to be dumped from the drying chamber to the storage chamber before the unit can be re-started. This error indicates that either the drying chamber High Level Rotary switch is faulty or the time on the load delay or Aux.

  • Page 24: Valve Proving System

    9. Error Messages and Valve Proving System Grain High-Limit The grain temperature in the drying chamber is too high. Valve Proving System The main safety shut off valve is fitted with a proving system which will prevent burner start-up if the valve is leaky.

  • Page 25: Chapter 10 Initial Start-Up

    10. Initial Start-Up Dryer Commissioning Electrical 1. Carry out earth bonding test per EN60204 and/or local electrical laws and regulations. 2. Check adequate power supply. (Refer to electrical specifications Table on Page 11.) 3. Voltage at phases must be within 5% of rated voltage. 4.
  • Page 26 10. Initial Start-Up Gas Train (Continued) 6. Set burner low-fire pressure. • Set plenum temperature to approx. 10°C above ambient. • Light burners. • On low fire, adjust high-low valve minimum setting to give pressure as per fuel specifications Table on Page 7.

  • Page 27: Chapter 11 Pre-Season Checks

    11. Pre-Season Checks Before the dryer is filled, inspect the unit and check the operation of the dryer as follows. Never enter a bin where grain is present. Set Control Switches • Moisture Control switch - “ON” • Aeration Fan switch - “OFF” •...

  • Page 28: Control Power Switch

    11. Pre-Season Checks Control Power Switch Turn the control power switch ON. The switch will illuminate. If a fault is found an error message will be displayed on the screen. If all are found safe, the main drying screen will be displayed. (See Figure 11A.) Mount even with fan/heater...

  • Page 29: Drying Chamber

    11. Pre-Season Checks Drying Chamber Inspect each dump hopper for obstructions. Make sure that the gap between the discharge flow plates and the floor sheets is a minimum of 38 mm. Rotary Switches Check all rotary switches are spinning freely. Linear Actuator Turn the Dump switch “manual open”.

  • Page 30: Fill System

    11. Pre-Season Checks Fill System Prepare the wet storage tank to deliver grain to the dryer. Make sure all personnel clear. Switch load auger to “AUTO”. Grain should be delivered from the wet supply tank to the dryer. When the display shows “GRAIN LOW LEVEL YES” close the valve that supplies the fill system(s) with wet grain from the wet supply tank.

  • Page 31: Chapter 12 Autoflow Theory

    12. Autoflow Theory Top Dry Autoflow Theory of Operation Control Panel Switch Status • Control power: “ON” • Moisture control thermostat: “ON” • Aeration fan: “AUTO” • Load auger: “AUTO” • Fan: “AUTO” • Heater: “AUTO” • Dump: “AUTO” • Dry and hold: “OFF”...
  • Page 32 12. Autoflow Theory During the dump cycle 1/3 of the grain is dumped into the storage chamber. 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. The unit continues with the same operation until either no grain is present against the Wet Supply Rotary switch or the storage chamber becomes full.

  • Page 33: Chapter 13 Start-Up Procedure

    13. Start-Up Procedure Initial Dryer Start-Up 1. With Control Power switch OFF, turn ON the main power supply. 2. Pull out all Emergency Stop switches. 3. Set the switches as follows: • Moisture Control switch - “ON” • Aeration Fan switch - “AUTO” •...
  • Page 34 13. Start-Up Procedure 12. Set the grain temperature set point as follows: • 82°C Drying temperature = 38°C Grain temperature set point • 77°C Drying temperature = 39°C Grain temperature set point • 71°C Drying temperature = 41°C Grain temperature set point •...

  • Page 35: Normal Start-Up

    13. 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 36 NOTES PNEG-1820CE CE Compliant Top Dry Series 2000 Autoflow...

  • Page 37: Chapter 14 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 38 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 GSI is a worldwide brand of AGCO Corporation. Copyright © 2014 by GSI Group Printed in the USA CN-308613...

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Topdry ce 2000 autoflow

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