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Summary of Contents for GSi TopDry Terminal 24
- Page 1 TopDry Terminal™ for Autoflow/ Autobatch Operation Models: 24, 30, 36 FT DIAMETER Operation Manual PNEG–4900 Version 1.0 Date: 04-08-16 PNEG–4900...
- 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–4900 TopDry Terminal™...
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Page 3: Table Of Contents
Shutting off the Dryer in an Emergency ..................57 Initial Dryer Start-Up ........................58 Normal Start-Up ........................60 Drying Grain in Last Fill......................60 Shutting off the Dryer.........................60 Chapter 7 Troubleshooting ........................61 TopDry Terminal Error Messages....................61 GSI Group, LLC Limited Warranty ...................65 Pneg–4900 TopDry Terminal™... - Page 4 NOTES Pneg–4900 TopDry Terminal™...
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Page 5: Chapter 1 Safety Precautions
Safety Precautions Topics Covered in this Chapter ▪ Safety Guidelines ▪ Cautionary Symbol Definitions ▪ Safety Cautions ▪ Safety Decals ▪ Safety Sign-off Sheet Safety Guidelines Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is written to help you understand safe operating procedures and problems that can be encountered by the operator and other personnel when using this equipment. -
Page 6: Cautionary Symbol Definitions
Chapter 1: Safety Precautions Cautionary Symbol 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. Table 1-1 Description of the different cautionary symbols Symbol Description... -
Page 7: Safety Cautions
Chapter 1: Safety Precautions Safety Cautions Use Personal Protective Equipment • Use appropriate personal protective equipment: Respiratory Foot Protection Protection Protection Hearing Head Fall Protection Protection Protection Hand Protection • Wear clothing appropriate to the job. • Remove all jewelry. •... - Page 8 • Make sure grain chutes are empty by performing a manual dump before entering the bin. • Before attempting to remove and reinstall the fan blade, con- tact GSI for the recommended procedure. ST-0031–2 For Your Safety • If you smell gas: —...
- Page 9 • The operating instructions in this manual pertain to the common cereal grains as indicated. When drying any other grain, contact GSI for additional recommendations. • On LP fired units, set pressure regulator to avoid excessive gas pressure applied to the burner during ignition and opera- tion.
- Page 10 Chapter 1: Safety Precautions Exercise Caution When Drying Flammable Grains • Be aware that some grains are highly flammable including, but not limited to, rapeseed, canola, linseed, sunflower and milo. • All grain and seed must be whole (minimal cracking or crush- ing), clean, and dust free before drying.
- Page 11 Chapter 1: Safety Precautions Prevent Roof Damage Due to Vacuum Pressure • Roof damage can result from excessive vacuum or internal pressure from fans or other air moving systems. The manu- facturer does not warrant this type of roof damage. •...
- Page 12 Chapter 1: Safety Precautions Store Bin Sheets Properly • Sidewall bundles or sheets must be stored in a safe manner. The safest method of storing sidewall bundles is by laying them horizontally with the arch of the sheet upward, like a dome.
- Page 13 Chapter 1: Safety Precautions Confined Space Hazards and Entry Procedures • Note that the interior of this equipment is considered a con- fined space. Maintenance of this equipment can require access to the confined space. • Access doors must be shut and locked except when access is required.
- Page 14 Chapter 1: Safety Precautions Fall Hazard • Ladders, stairways and platforms are for use by competent and trained personnel only. Do not allow children or other unauthorized persons to have access to the equipment. • Access to the equipment must be restricted by the use of security fencing and lockable gates.
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Page 15: Safety Decals
The safety decals on your equipment are safety indicators which must be carefully read and understood by all personnel involved in the installation, operation, service and maintenance of the equipment. To replace a damaged of missing decal, contact us to receive a free replacement. GSI Decals 1004 E. Illinois Street Assumption, IL 62510 Phone: 1–217–226–4421... - Page 16 Chapter 1: Safety Precautions Location Decal No. Decal Description Danger Keep Clear of On bin door DC-GBC-1A Augers covers On bin door Warning Unload Instructions DC-GBC-2A covers Pneg–4900 TopDry Terminal™...
- Page 17 Chapter 1: Safety Precautions Fan and Heater Decals Location Decal No. Decal Description Fan and Heater High Voltage Danger Decal DC-1943 Unit Fan and Heater High Voltage Danger Decal DC-1948 Unit Fan and Heater Rotating Blade Warning DC-1949 Unit Decal Flame and Pressure Warn- Fan and Heater DC-1959...
- Page 18 Chapter 1: Safety Precautions Location Decal No. Decal Description Fan and Heater Flammable Vapor Warning DC-2331 Unit Decal Fan and Heater Flammable Vapor Warning DC-2392 Unit Decal Pneg–4900 TopDry Terminal™...
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Page 19: Safety Sign-Off Sheet
Chapter 1: Safety Precautions Safety Sign-off Sheet Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety instructions. This sign-off sheet is provided for your convenience and personal record keeping. Date Employee Name Supervisor Name... - Page 20 NOTES Pneg–4900 TopDry Terminal™...
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Page 21: Chapter 2 The Topdry™ System
The TopDry™ System Topics Covered in this Chapter ▪ Overview of the TopDry Grain Dryer ▪ Location of TopDry Components and Accessories ▪ TopDry Terminal Drying Capacities ▪ Storage Capacity Overview of the TopDry Grain Dryer The TopDry Grain Dryer is a grain bin with the addition of a peaked drying floor inside the top of the bin. The grain flows into the top of the bin and special leveling bands keep the grain at a uniform depth. -
Page 22: Location Of Topdry Components And Accessories
Chapter 2: The TopDry™ System Location of TopDry Components and Accessories Use the following as a suggested guideline for placing the TopDry components and accessories. When locating the manway, make sure that the outside ladder will not interfere with other accessories below. - Page 23 Chapter 2: The TopDry™ System Figure 2-3 Location of TopDry Components and Accessories — Side View Fill system no. 2 Grain temperature sensor junction box Fill system no. 1 Control fan/heater Aeration fan Plenum temperature sensor TopDry drying bin Fan/heater (Secondary) Grain temperature sensors TopDry Terminal control mounted at eye level Drying chamber rotary switch...
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Page 24: Topdry Terminal Drying Capacities
Chapter 2: The TopDry™ System TopDry Terminal Drying Capacities Table 2-1 Drying Rates for Shelled Corn TopDry Terminal Series 24' Dia. 1-Fan 30' Dia. 1-Fan 30' Dia. 2-Fan 36' Dia. 1-Fan 36' Dia. 2-Fan Mois- ture Dump Dump Dump Dump Dump Fan &... -
Page 25: Storage Capacity
Chapter 2: The TopDry™ System Storage Capacity Table 2-2 Storage Capacity Maximum Grain in Dump Size (BU) Rings Eave Height Peak Height Bin Diameter Process (BU) Storage (BU) 4,373 18'-5" 25'-0" 5,758 22'-1" 28'-8" 7,143 25'-9" 32'-4" 24 ft. 8,528 29'-5"... - Page 26 NOTES Pneg–4900 TopDry Terminal™...
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Page 27: Chapter 3 Gas And Electrical Specifications
Gas and Electrical Specifications Topics Covered in this Chapter ▪ The Fuel Supply ▪ Electrical Load Information The Fuel Supply You can choose either Liquid Propane (LP) or Natural Gas (NG) to fuel the heater(s) for your TopDry. Liquid Propane If using LP gas, make sure to slowly open the main fuel supply valve at the supply tank. -
Page 28: Electrical Load Information
Chapter 3: Gas and Electrical Specifications Electrical Load Information The chart below is a reference for the electrician wiring the grain dryer. It is recommended that you con- tact your local power company and have a representatives survey the installation to make sure that the wiring is compatible with their system and that adequate power is supplied to the unit. - Page 29 Chapter 3: Gas and Electrical Specifications Figure 3-1 Electrical Load Information Breaker Motors Entrance panel Fill system control Starters in fill system control Pneg–4900 TopDry Terminal™...
- Page 30 NOTES Pneg–4900 TopDry Terminal™...
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Page 31: Chapter 4 Control Panels
Control Panels Topics Covered in this Chapter ▪ The TopDry Terminal Control Panel ▪ Powering on the Touch Screen ▪ Overview of the User Interface ▪ Configuring the Operational Settings for the TopDry Terminal ▪ The Timer and Delay Menu ▪... -
Page 32: The Topdry Terminal Control Panel
Chapter 4: Control Panels The TopDry Terminal Control Panel Along with the touchscreen user interface, the control panel contains all buttons and switches that allow you to set up and operate your dryer. Figure 4-1 The TopDry Terminal NOTE: Images of the dryer, control panel, and user interface menus that are included in this guide are for illustrative purposes only and may not entirely resemble the actual product. - Page 33 Chapter 4: Control Panels Table 4-1 The components of the TopDry Terminal (cont'd.) Item Name Description Control power switch Controls the power to the TopDry system by way of the following modes: • Off: the TopDry Terminal will not operate •...
- Page 34 Chapter 4: Control Panels Table 4-1 The components of the TopDry Terminal (cont'd.) Item Name Description Fan switch Controls the main drying fans by way of the following modes: • Off: the main drying fan(s) do not operate • On: The main drying fan(s) will operate continuously in both Autobatch and Autoflow modes, except during the grain dump cycle, where the fan(s) will shut-off for a pre-set time that is programmed into the Fan OFF Delay settings...
- Page 35 Chapter 4: Control Panels Table 4-1 The components of the TopDry Terminal (cont'd.) Item Name Description Dryer Power button This button energizes the control switches and operates the dryer based on the switch settings. Note the following: • The Dryer Power button illuminates when the dryer is operating. •...
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Page 36: Powering On The Touch Screen
Chapter 4: Control Panels Powering on the Touch Screen What You Should Know The Touch Screen on the TopDry Terminal allows you to configure all timing functions, temperature con- trols, safety circuit checks and dryer setup parameters while also providing an animated representation of the TopDry operation. - Page 37 Chapter 4: Control Panels Figure 4-3 The main menu with all displays shown NOTE: Due to the numerous configurations and options available, images of the dryer and it’s user interface that are included in this guide can differ from the actual product. Any Rotary Switch that is disabled will not appear on the main screen.
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Page 38: Configuring The Operational Settings For The Topdry Terminal
Chapter 4: Control Panels Table 4-2 Description of the main menu’s buttons and displays (cont'd.) Item Name Description Grain temperature set- Shortcut that allows you to quickly modify the setpoint temperature of the point button grain; displays the current grain temperature setpoint Plenum temperature Shortcut that allows you to quickly modify the setpoint temperature of the setpoint button... - Page 39 Chapter 4: Control Panels Figure 4-4 The setup menu Item — Name Item — Name 1 — Drying mode 12 — Low level switch 2 — Discharge mode 13 — Drying chamber overflow 3 — Switch selection 14 — Start fans with high level 4 —...
- Page 40 Chapter 4: Control Panels Discharge Mode — Selects how the system determines when the grain is discharged from the dump chutes. The available discharge modes are the following: • Time only mode: The grain is dumped at the end of its drying cycle based strictly on the time set in the Dry Timer setting.
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Page 41: The Timer And Delay Menu
Chapter 4: Control Panels The Timer and Delay Menu You can access and set all parameters for the timers and delays from the same menu. The figure that fol- lows illustrates and describes the parameter fields. Figure 4-5 Timers and delays menu Item —... -
Page 42: Setting The Delays
Chapter 4: Control Panels • The Dry Timer sets the amount of time the burner operates during a drying cycle. The setting is based on the moisture content of the grain being dried. Refer to TopDry Terminal Drying Capacities, page •... -
Page 43: The Temperature Menu
Chapter 4: Control Panels • The Low Level Switch Delay sets the amount of time the drying chamber low level switch can be uncovered, indicating the drying chamber is low on grain, before the dryer will shut down. NOTE: This is to prevent nuisance shutdowns and must normally be left at the default setting. •... -
Page 44: Setting The Sensors And Temperature Limits
Chapter 4: Control Panels Figure 4-6 The temperature menu Item — Name Item — Name 8 — Plenum temperature setpoint 1 — Grain temperature sensors 2 — Grain sensor temperature (1– 4) 9 — Temperature limits 3 — Grain sensor temperature offset (1– 4) 10 —... - Page 45 Chapter 4: Control Panels 5. Set the temperature setpoints for the plenum and grain temperature by clicking on the dark blue area of the Grain Temp Setpoint and Plenum Temp Setpoint buttons. NOTE: The number displayed in the light blue area is the current temperature of the drying grain and the plenum.
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Page 46: Setting The Temperature Setpoints For The Plenum And Grain From The Main Screen
Chapter 4: Control Panels Setting the Temperature Setpoints for the Plenum and Grain from the Main Screen By clicking the blue buttons in the upper right hand corner of the main menu, you can configure the tem- perature setpoints for the plenum and grain. These settings can also be set from the temperature screen. What You Should Know The current plenum temperature is displayed in a black box in the heat plenum (storage) area of the dryer illustration. -
Page 47: The Information Menu
Chapter 4: Control Panels The Information Menu The information menu allows you to view alarms, setup Watchdog message, view operation history and access to a graphic diagnostic display of the control boards. Table 4-3 The information menu Item Name Description Event log Allows you to view the alarm history. -
Page 48: Factory Default Settings
Chapter 4: Control Panels Factory Default Settings You can reference the default factory settings to compare them with any changes you may have made. Table 4-4 TopDry Terminal Default Settings Factory Value Parameter Units Drying Mode AutoFlow Time or Time/Temp Dry Time &... -
Page 49: The Fill System Control
Chapter 4: Control Panels The Fill System Control The fill system control box houses the motor starters for fill system 1, fill system 2 and the aeration fan(s). You can set the switches to determine the mode of operation for the fill system and aeration fan(s). Figure 4-8 Fill System Control Table 4-5 The components of the fill system control Item... - Page 50 Chapter 4: Control Panels Table 4-5 The components of the fill system control (cont'd.) Item Name Description Fill system 2 switch Controls the secondary load auger by way of the following modes: • Off: the load auger does not operate •...
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Page 51: Chapter 5 Getting Started
Getting Started Topics Covered in this Chapter ▪ Pre-Season Inspections ▪ Testing and Leveling the Dump Chutes ▪ Testing the Fill System ▪ Testing the Aeration Fan ▪ Testing the Air Switch ▪ Testing the Burner Pre-Season Inspections Before the dryer is started or filled, fully inspect the TopDry system to ensure all components are in good working order. -
Page 52: Testing And Leveling The Dump Chutes
Chapter 5: Getting Started Fans • Make sure fans rotate freely in the correct direction. Electrical Components • Make sure there are no loose or bare wires. Testing and Leveling the Dump Chutes Before attaching the sprocket chain to the lift plate cable, you must test that the sprocket travels from the open limit switch position to the close limit switch position. -
Page 53: Testing The Fill System
Chapter 5: Getting Started The dump chutes should be fully open. 8. Inspect the dump chutes, and if they are not fully open, loosen the double nuts on the hinge bolts. 9. Re-install all guarding and enclosures. 10.Set the Dump switch on the TopDry Terminal to the Auto position and press the Stop button. The dump chutes should raise to the closed position. -
Page 54: Testing The Aeration Fan
Chapter 5: Getting Started • Prepare the wet storage tank to deliver grain to the dryer. • Turn all switches on the TopDry Terminal to OFF. • Turn the Control Power switch to ON. • Push the Dryer Power Start button. To test the fill system: Make sure all personnel are away from any equipment controlled by the TopDry Terminal. -
Page 55: Testing The Air Switch
Chapter 5: Getting Started Testing the Air Switch Airflow must be detected by the air switch before the heaters will begin to operate. Before You Begin • Make sure you have completed the pre-season inspections. • E-Stops are pulled out. •... - Page 56 Chapter 5: Getting Started The burner will light after the purge delay and the light in the heater switch will blink during the purge and ignition period. Once a flame is sensed, the light will stop flashing and remain on. 3.
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Page 57: Chapter 6 Operation
Operation Topics Covered in this Chapter ▪ Shutting off the Dryer in an Emergency ▪ Initial Dryer Start-Up ▪ Normal Start-Up ▪ Drying Grain in Last Fill ▪ Shutting off the Dryer Shutting off the Dryer in an Emergency What You Should Know Never disable an Emergency Stop. -
Page 58: Initial Dryer Start-Up
Chapter 6: Operation Initial Dryer Start-Up Before You Begin • Make sure to complete all pre-season checks and tests. Refer to Pre-Season Inspections, page • Make sure there is wet grain in the wet supply tank. • Make sure all personnel are clear from the TopDry and loading systems before starting or operating your equipment. - Page 59 Chapter 6: Operation 11.Set the Grain Temperature Setpoint as follows: • 180°F Drying temperature = 100°F Grain temperature set point • 170°F Drying temperature = 103°F Grain temperature set point • 160°F Drying temperature = 105°F Grain temperature set point •...
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Page 60: Normal Start-Up
Chapter 6: Operation 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 61: Chapter 7 Troubleshooting
Troubleshooting Topics Covered in this Chapter ▪ TopDry Terminal Error Messages TopDry Terminal Error Messages Error Message Cause/Remedy Thermal overload on Fill Conveyor #1 located in the fill box has tripped. Fill #1 Conveyor Overload The overload must be manually reset. Thermal overload on Fill Conveyor #2 located in the fill box has tripped. - Page 62 Chapter 7: Troubleshooting Error Message Cause/Remedy Check the dump chute drive VFD and make sure the display is powered Dump Chutes Did Not Open on and that there is no fault code on its display. Check the dump chute drive VFD and make sure the display is powered Dump Chutes Did Not Close on and that there is no fault code on its display.
- Page 63 Chapter 7: Troubleshooting Error Message Cause/Remedy The mechanical 250 degree plenum temp hi-limit has opened. Check for Heater 1 Digital Plenum Temp Hi- possible fire or overheated grain. Limit The optional gas pressure switch on heater #1 fuel train has opened. Heater 1 Gas Pressure Out of Range Reduce gas pressure.
- Page 64 Chapter 7: Troubleshooting Error Message Cause/Remedy The air switch located in the fan #2 electrical box has opened after initially closing. The air switch needs adjustment or airflow to or from fan #1 is Heater 2 Air Flow Lost being restricted. The air switch is closed without fan #2 running.
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Page 65: Gsi Group, Llc Limited Warranty
12 months after sale to the original end-user or if a foreign sale, 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... - Page 66 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 © 2016 by The GSI Group, LLC Printed in the USA CN #323226...
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