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GSI Group II Sweep Series Owner's Manual

12" and 16" series ii sweep quick disconnect control box kit
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12" and 16" Series II Sweep
Quick Disconnect Control Box Kit
Owner's Manual
PNEG-1366
Date: 12-21-20
PNEG-1366

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Summary of Contents for GSI Group II Sweep Series

  • Page 1 12" and 16" Series II Sweep Quick Disconnect Control Box Kit Owner’s Manual PNEG-1366 Date: 12-21-20 PNEG-1366...
  • Page 2 Model Number : Date Delivered: Date Installed: Notes: Personnel operating or working around this equipment should read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment. Any misuse of the equipment may void the warranty. PNEG-1366 12"...

  • Page 3: Table Of Contents

    Table of Contents Contents Chapter 1 Product Overview ..........................5 Chapter 2 Safety ..............................6 Safety Guidelines ..........................6 Safety Instructions ..........................7 Operator Qualifications ........................11 Chapter 3 Decals ..............................12 Chapter 4 Introduction ............................15 General Information ..........................15 Capacities and Specifications ......................16 Chapter 5 Assembly ............................18 Docking Station Mount ........................
  • Page 4 Table of Contents Chapter 12 Parts List ............................45 Control Panel Components Pre-June 2010 Style Panel ..............46 Quick Detach Control Panel Assembly (GC10115) Pre-June 2010 ..........48 Control Box Base Assembly (GC10109) (for Quick Detach Control Panel) Pre-June 2010 ....49 Dock Station Assembly (GC10116) (for Quick Detach Control Panel) Pre-June 2010 .....

  • Page 5: Chapter 1 Product Overview

    1. Product Overview The Quick Disconnect Control Box was designed to work 12" and 16" GSI Series II Sweeps.This Quick Disconnect Control Box modular design will allow you to move the control box to each sweep location, therefore only one control box is needed to control all of the same size sweeps. Each sweep location will require a docking station for the control box base to slide into.

  • Page 6: Chapter 2 Safety

    2. 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 7: Safety Instructions

    2. Safety Safety Instructions 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 which 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.
  • Page 8 2. Safety Lifting Hazard Do not lift equipment without personal or mechanical assistance. Single person lift could cause injury. To avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing the control box. Use Proper Lifting Equipment Install and Operate Equipment Properly...
  • Page 9 2. Safety Practice Safe Maintenance ALWAYS turn off and lock out all power sources before Lock Out performing any maintenance. Power Keep Work Understand service procedures before doing work. Area Clean Keep area clean and dry. Never lubricate, service, or adjust machine while it is in operation.
  • Page 10 2. Safety Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate Eye Protection to the job. Remove all jewelry. Gloves Long hair should be tied up and back. Safety glasses should be worn at all times to protect eyes from debris.

  • Page 11: Operator Qualifications

    2. Safety Operator Qualifications A. The User/Operator must be competent and experienced to operate auger equipment. Anyone who works with or around augers must have good common sense in order to be qualified. These persons must also know and meet all other qualifications, such as: i.

  • Page 12: Chapter 3 Decals

    3. Decals Figure 3A shows the location of the decals and safety signs which should appear on the Control Panel and Quick Disconnect Control Kit. NOTE: Please remember safety signs provide important safety information for people working near bin unloading equipment that is in operation. Any safety signs that are worn, missing, illegible or painted over should be replaced immediately.
  • Page 13 3. Decals DC-1756 DC-1756 A) DC-1756 Location: Corners of mounting plate. Size: 4-3/4" x 2-1/4" DC-889 B) DC-889 Location: Interior of control panel. On electrical boxes. Size: 2-13/16" x 1-7/16" DC-1224 DC-1224 C) DC-1224 Location: Corner of control panel. Size: 2-7/8" x 5" PNEG-1366 12"...
  • Page 14 3. Decals A. DANGER Sign No. DC-1395 was supplied with your bin unloading equipment. This safety sign should be applied to the side of the bin near the bin opening, so it will be viewed by people entering into the bin storage building. Do not cover any safety signs or any other signs that are already there.

  • Page 15: Chapter 4 Introduction

    4. Introduction NEVER enter a grain bin unless ALL power driven equipment has been shut down. Disconnect and lock out power before entering the bin or servicing the equipment. General Information 1. GSI reserves the right to improve its product whenever possible and practical to do so. We reserve the right to change, improve and modify products at any time without obligation to make changes, improvements and modifications on equipment sold previously.

  • Page 16: Capacities And Specifications

    4. Introduction Capacities and Specifications Electrical controls and wiring should be installed by a qualified electrician. The motor disconnect switches and conductor cables should comply with the National Electrical code and any local codes which apply. Reset and motor starting stations should be located so the operator can see that all personnel are clear of the equipment.
  • Page 17 4. Introduction NOTE: The horsepower recommendations are for augering reasonably dry grain. High moisture grain (greater than 15%) will require greater power for maximum capacity. The maximum capacity will be less with high moisture grain than with dry grain. Sweep drive and carrier wheels require plates or track over aeration flooring for travel and supports not supplied with the sweep unit.

  • Page 18: Chapter 5 Assembly

    5. Assembly Docking Station Mount Securely mount the docking station outside of the bin near the bin door. Figure 5A shows the hole pattern and diameter. The docking station must be close enough to the bin door to plug in the 10' long foot switch cord.

  • Page 19: Control Panel Conduit Hole (Pre-June 2010)

    5. Assembly Control Panel Conduit Hole (Pre-June 2010) NOTE: The Series II Sweep has used different control boxes. The quick disconnect kit will fit either style box. Hardware is provided to mount an older style box (with ears) to the mounting plate. The new style box already has hardware installed in the rear of the box.

  • Page 20: Control Panel Installation

    5. Assembly Control Panel Installation Electrical controls should be installed by a qualified electrician and must meet standards set by the National Electrical Code and all local and state codes. A main power disconnect switch capable of being locked only in the OFF position should be used.
  • Page 21 5. Assembly Based on where the outlet for the drop cord is installed on the panel, all three (3) mounting positions may not be possible. (See Figure 5D.) Figure 5D A sample installation configuration is shown in Figure 5E for the auger drive power outlet, tractor drive power outlet, overload for motor control outlet and the drop cord outlet.

  • Page 22: Guidance Handle Installation

    5. Assembly Install each receptacle to the panel with the supplied hardware. Consult the wiring schematic in the panel enclosure for proper electrical connection locations. Once the receptacles have been properly installed, the auxiliary guidance handles can be attached to the panel assembly.
  • Page 23 5. Assembly Figure 5G PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 24: Place Control Panel Into Docking Station

    5. Assembly Place Control Panel Into Docking Station Attach the control box to the docking station by sliding the tongue into the pocket on the docking station. (See Figure 5H.) Do not lift equipment without personal or mechanical assistance. Single person lift could cause injury.

  • Page 25: Control Panel Setup

    5. Assembly Control Panel Setup NOTE: The control panel may have to be reprogrammed for peak performance after being moved to a different bin. The bin must have grain in it to be able to properly fine tune the control panel. If the meter looks like this: Figure 5I Control Panel Calibration...
  • Page 26 5. Assembly Initial Display Setup NOTE: If no keys are activated for 2 minutes, the display returns to the default state without saving any configuration changes. At each value, after 5 seconds of inactivity, a description of the current state will scroll across the display. NOTE: Pressing and hold OK will return to the previous menu or return to the default state without saving the changed values or parameters.
  • Page 27 5. Assembly Switch the Manual Mode switch to idle (not reverse or forward). Depress the pedal in the safety foot switch. Press the Start button on the control panel. NOTE: If any damage is observed or there is abnormal operation of the sweep, shut it down immediately. There are three (3) ways to accomplish this.
  • Page 28 5. Assembly HYS1 should be displayed on the unit. For this control panel hysteresis (HYS1) is measured as the different between 90% of full load amps and 110% of no load amps. 90% of full load amps: ____ minus 110% of no load amps: ____ Press on the display unit until the correct value is shown.
  • Page 29 5. Assembly If you select NO, press OK. If you select YES, N.PAS will be displayed. Press on the display unit until your password is shown. Press OK. Document this password. The password will be necessary if there needs to be changes to many of the configuration values. If the meter looks like this: Figure 5J Follow these instructions:...

  • Page 30: Calibration

    5. Assembly Calibration 1.Setting Input a. Press “PRGM” to “inPut”. b. Press “ENTER”. c. Press “PRGM” to “i4-20”. d. Press “ENTER” to RUN MODE. 2. Setting Setup a. Press “PRGM” to “SEtuP”. b. Press “ENTER” to “rdEC” Use arrow buttons to change the decimal placement. Show .0 Amps. c.

  • Page 31: Operation

    5. Assembly Operation 1. Setting Presets a. Press “Pre A”. b. Press “PRGM” This value = “High Amp Set Point”. Use arrow buttons to change value. c. Press “ENTER”. 2. Setting Relays a. Press “PRGM” to “rELAYS”. b. Press “ENTER” to “HYS A”. c.

  • Page 32: Chapter 6 Start-Up

    6. Start-Up Perform Pre-Start Checks To ensure that the drive is not unexpectedly started, turn OFF and lock out the power source before proceeding. Failure to observe these precautions could result in bodily injury. Failure to perform any or all of these pre-start checks may cause damage to the equipment and/or cause SERIOUS INJURY or DEATH to those in the work area.

  • Page 33: Start The Auger

    6. Start-Up Start the Auger DO NOT start or stop the auger while it is under load. 1. Plug the two (2) motors, foot switch and thermal protection cords into the bottom of the control panel while making sure they are locked into the receptacles. Each plug is different and can only be plugged into one receptacle to prevent accidental electric shock and/or overloads.

  • Page 34: Chapter 7 Operation

    7. Operation Operating the Sweep Auger Gear reducer is shipped without oil. Add the proper amount of the recommended lubricant before operating. Failure to observe these precautions could result in damage to, or destruction of, the equipment. Keep out of the bin while the bin sweep auger is in operation. The rapidly moving sweep auger can cause SERIOUS INJURY or DEATH.

  • Page 35: Operating The Sweep Auger Control Panel

    7. Operation Operating the Sweep Auger Control Panel A. The sweep operates in two (2) different “modes”. 1. Automatic (The auger motor runs and the drive motor runs using the Amp Meter in the control panel.) Step on the foot switch and press the “Start” button. The auger motor will turn ON and the drive motor will turn ON only if the Amp Meter reaches the “Low”...

  • Page 36: Chapter 8 Shut Down

    8. Shut Down Normal Shut Down 1. Before shutting down the unit, be sure the sumps and unload conveyor are empty. 2. Press the “Stop” button on the control panel. Emergency Shut Down 1. Know how to shut down the auger in case of an emergency. 2.

  • Page 37: Chapter 9 Maintenance

    9. Maintenance Maintain the Auger ALWAYS shut down and disconnect the power supply before adjusting, servicing or cleaning the equipment. A. Use caution when repairing or replacing equipment parts. B. Make sure ALL decals are legible and securely attached to the auger. If necessary, replace them FREE OF CHARGE by contacting GSI at: P.O.

  • Page 38: Chapter 10 Control Panel Diagrams

    10. Control Panel Diagrams Series II Sweep Control Package - 08-32A:3-12A, Non-575V (S2PFA) Series II Sweep Control Package - 08-32A:3-12A, Non-575V (S2PFA) Auger Drive Motor Amps Tractor Drive Motor Amps Voltage Auger Drive HP Tractor Drive HP 2 - 7-1/2 3/4-3 3-10 8-32...

  • Page 39: Series Ii Sweep Control Package - 30-40A:3-12A, Non-575V (S2Pfb)

    10. Control Panel Diagrams Series II Sweep Control Package - 30-40A:3-12A, Non-575V (S2PFB) Series II Sweep Control Package - 30-40A:3-12A, Non-575V (S2PFB) Auger Drive Motor Amps Tractor Drive Motor Amps Voltage Auger Drive HP Tractor Drive HP 3/4-3 30-40 3-12 20-25 3 - 7-1/2 25-30...

  • Page 40: Series Ii Sweep Control Package - 08-32A:3-12A, 575V Only (S2Pfc)

    10. Control Panel Diagrams Series II Sweep Control Package - 08-32A:3-12A, 575V Only (S2PFC) Series II Sweep Control Package - 08-32A:3-12A, 575V Only (S2PFC) Auger Drive Motor Amps Tractor Drive Motor Amps Voltage Auger Drive HP Tractor Drive HP 8-32 3-12 7-1/2 - 30 2-10...

  • Page 41: Control Panel Schematic (460/3/60) Pre-June 2010

    10. Control Panel Diagrams Control Panel Schematic (460/3/60) Pre-June 2010 PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 42: Control Panel Schematic (230/3/60) Pre-June 2010

    10. Control Panel Diagrams Control Panel Schematic (230/3/60) Pre-June 2010 PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 43: Control Panel Schematic (380/3/50) Pre-June 2010

    10. Control Panel Diagrams Control Panel Schematic (380/3/50) Pre-June 2010 PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 44: Chapter 11 Troubleshooting

    11. Troubleshooting Problem Possible Cause Solution 1. Power cords may be unplugged. 1. Plug in the power cords. 2. Make sure the foot switch is depressed and 2. Foot switch may not be actuated. the switch is operating properly. 1. Sweep does not run. 3.

  • Page 45: Chapter 12 Parts List

    12. Parts List 1. Control Panel Components Pre-June 2010 Style Panel 2. Quick Detach Control Panel Assembly (GC10115) Pre-June 2010 3. Control Box Base Assembly (GC10109) (for Quick Detach Control Panel) Pre-June 2010 4. Dock Station Assembly (GC10116) (for Quick Detach Control Panel) Pre-June 2010 5.

  • Page 46: Control Panel Components Pre-June 2010 Style Panel

    12. Parts List Control Panel Components Pre-June 2010 Style Panel PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...
  • Page 47 12. Parts List Control Panel Components Pre-June 2010 Style Panel Parts List Ref # Part # Description DC-1224 Decal, Danger, High Voltage DC-1536 Decal, Series II Sweep Panel Overlay DC-889 Decal, Danger, High Voltage GC03659 Switch, Standard - Round - Push Button - Plastic - Flush - Red GE (#P9XPNRG) GC03666 Receptacle, 3P4W, 50A, 3 PH, 480V - CS8169 GC03667...

  • Page 48: Quick Detach Control Panel Assembly (Gc10115) Pre-June 2010

    12. Parts List Quick Detach Control Panel Assembly (GC10115) Pre-June 2010 Quick Detach Control Panel Assembly (GC10115) Pre-June 2010 Parts List Ref # Part # Description GC10109 Control Box Base GC10116 Dock Station Assembly GC10079 Drop Cord PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 49: Control Box Base Assembly (Gc10109) (For Quick Detach Control Panel) Pre-June 2010

    12. Parts List Control Box Base Assembly (GC10109) (for Quick Detach Control Panel) Pre-June 2010 Control Box Base Assembly (GC10109) Parts List Ref # Part # Description GC10107 Base Back Plate Weldment GC10071 Box, S2S2 Electrical Back BB602W 60A with 1-1/2" Hub Hubell GC10073 Inlet S-6998...

  • Page 50: Dock Station Assembly (Gc10116) (For Quick Detach Control Panel) Pre-June 2010

    12. Parts List Dock Station Assembly (GC10116) (for Quick Detach Control Panel) Pre-June 2010 Dock Station Assembly (GC10116) Parts List Ref # Part # Description GC10103 S2S2 Fixed Base Weldment - Kid Control Box GC10071 Box, S2S2 Electrical Back BB602W 60A with 1-1/2" Hub Hubell GC10072 Receptacle S-6998...

  • Page 51: Conduit Assembly (Gc10113) (For Quick Detach Control Panel)

    12. Parts List Conduit Assembly (GC10113) (for Quick Detach Control Panel) Conduit Assembly (GC10113) Parts List Ref # Part # Description GC10111 Elbow, 1-1/2" Conduit GC10110 Hub, 1-1/2" Conduit GC10112 Nipple, 1-1/2" Conduit PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 52: Drop Cord Assembly (Gc10079) (For Quick Detach Control Panel) Pre-June 2010

    12. Parts List Drop Cord Assembly (GC10079) (for Quick Detach Control Panel) Pre-June 2010 Drop Cord Assembly (GC10079) Parts List Ref # Part # Description GC10078 S2S2 Electrical Cable for Drop Cord GC10074 Plug, Male GC10075 Plug, Female PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 53: Quick Detach Control Panel Receptacles Parts

    12. Parts List Quick Detach Control Panel Receptacles Parts Quick Detach Control Panel Receptacles Parts List Ref # Part # Description GC11769 Receptacle, Female, 3P4W, 60A, 3 PH, 600V - HBL460R5W S2PFA Series II Sweep Control Package - 08-32A:3-12A, Non-575V S2PFB Series II Sweep Control Package - 30-40A:3-12A, Non-575V S2PFC...

  • Page 54: Quick Detach Control Panel Package (Gk80112)

    12. Parts List Quick Detach Control Panel Package (GK80112) Quick Detach Control Panel Package (GK80112) Parts List Ref # Part # Description GK80110 Lift Base Dock Assembly GK80108 Lift Base Panel Assembly GK80111 Drop Cord Assembly PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 55: Lift Base Panel Assembly (Gk80108)

    12. Parts List Lift Base Panel Assembly (GK80108) Lift Base Panel Assembly (GK80108) Parts List Ref # Part # Description GK80106 Lift Base Panel Welded Assembly F-7050 Plastic Handle S-9315 Screw, SMSAB 1/4" x 1-1/4" HWHS ZN DC-1756 Decal, Warning, Lifting Hazard GC11769 Receptacle, Female, 3P4W, 60A, 3 PH, 600V - HBL460R5W S-8166...

  • Page 56: Lift Base Dock Assembly (Gk80110)

    12. Parts List Lift Base Dock Assembly (GK80110) Lift Base Dock Assembly (GK80110) Parts List Ref # Part # Description GC10103 S2S2 Fixed Base Weldment - Kid Control Box GC10071 Box, S2S2 Electrical Back BB602W 60A with 1-1/2" Hub Hubell GC11769 Receptacle, Female, 3P4W, 60A, 3 PH, 600V - HBL460R5W DC-889...

  • Page 57: Drop Cord Assembly (Gk80111)

    12. Parts List Drop Cord Assembly (GK80111) Drop Cord Assembly (GK80111) Parts List Ref # Part # Description GC10078 S2S2 Electrical Cable for Drop Cord GC11770 Plug, Male, 3PW4, 60A, 3 PH, 600V - HBL460P5W PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...
  • Page 58 NOTES PNEG-1366 12" and 16" Series II Sweep Quick Disconnect Control Box Kit...

  • Page 59: Chapter 13 Warranty

    Limited Warranty — N.A. Grain Products The GSI Group, LLC. (“GSI”) warrants products which it manufactures, to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months from the date of shipment (or, if shipped by vessel, 14 months from the date of arrival at the port of discharge).
  • Page 60 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 © 2010 by GSI Group Printed in the USA...

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