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GSI Group 700 Bu/Hr Owner's Manual

Pneumatic grain conveying
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Pneumatic Grain Conveying
4" - 700 Bu/Hr
5" - 1200 Bu/Hr
5" - 1700 Bu/Hr
Owner's Manual
PNEG-1563
Date: 07-27-09
PNEG-1563

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  • Page 1 Pneumatic Grain Conveying 4" - 700 Bu/Hr 5" - 1200 Bu/Hr 5" - 1700 Bu/Hr Owner’s Manual PNEG-1563 Date: 07-27-09 PNEG-1563...
  • Page 2 Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 3: Table Of Contents

    Table of Contents Contents Chapter 1 Safety ..........................5 Safety Guidelines ........................ 5 Chapter 2 Decals ..........................9 Chapter 3 Maintenance ........................11 Maintenance Schedule ...................... 11 Chapter 4 Air System ........................12 Air System Capacities (Dry Shelled Corn) ................ 12 Capacity Chart (4"...
  • Page 4 Table of Contents Chapter 12 Parts List ........................32 Blower Outlet Parts ......................33 4" (700) & 5" (1200) Standard Blower Parts ..............34 4" & 5" Twin Blower Parts ....................36 5" (1700) Hi-Capacity Blower Parts .................38 5" (1700) Twin Hi-Capacity Blower Parts .................40 4"...

  • Page 5: Safety Guidelines

    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 6: Chapter 1 Safety

    1. SAFETY Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs. Keep signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from the manufacturer.
  • Page 7 1. SAFETY Practice Safe Maintenance Understand service procedures before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is in operation. Stop and lock out power source before making adjustments, cleaning, or maintaining equipment. Keep all parts in good condition and properly installed.
  • Page 8 1. SAFETY Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Eye Protection Safety glasses should be worn at all times to protect eyes from debris. Wear gloves to protect your hands from Gloves sharp edges on plastic or steel parts. Wear steel toe boots to help protect your Steel Toe Boots toes from falling debris.
  • Page 9 Install safety decals on components as shown in the decal section. Always insure that safety decals are in a place, easily readable, and in good condition. If a decal cannot be easily read for any reason or has been painted over, replace it immediately. Contact your dealer or the manufacturer to order a replacement decal free of charge.

  • Page 10: Chapter 2 Decals

    2. DECALS DC-1386 DC-995 N10080 DC-994 DC-995 Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 11: Chapter 3 Maintenance

    Maintenance Schedule Initial Start-Up 1. Roots - Flo Blower 1. Oil level with middle of sight glass (DMC #MS5389 synth. oil). 2. Roots Blower 2. Oil level to check plug.* 3. Air Lock Gearbox 3. Oil level to check plug (SAE90). 4.

  • Page 12: Chapter 4 Air System

    4. AIR SYSTEM Air System Capacities (Dry Shelled Corn) Effective 700 Bu/Hr 1200 Bu/Hr 1700 Bu/Hr Length 4" System (Roots) 5" System (Roots) 5" System (Roots-Flo) (Feet) 10 HP 15 HP 20 HP 20 HP 30 HP 20 HP 30 HP...

  • Page 13: Chapter 5 Installation

    Air System Installation Instructions 1. Determine the most convenient location for the airlock and blower. Take into consideration the direction of the prevailing winds. It is important to locate the blower in as clean an environment as possible. This greatly reduces the maintenance requirements on the air filter system.

  • Page 14: Air System Capacities (Dry Shelled Corn)

    5. INSTALLATION 9. Measure the distance between the airlock and blower. Use flex hose or a combination of flex hose and galvanized tubing to connect the units together. Note that the grain discharge chute on the airlock is tapered and that grain can discharge in either direction. 10.

  • Page 15: Air System Tubing Dimensions

    5. INSTALLATION Air System Tubing Dimensions Figure 5B Reference Dimension 18' Dia 21' Dia 24' Dia 27' Dia 30' Dia 33' Dia 36' Dia 42' Dia 48' Dia 4" 25 31" 23" 47-1/2" 5-3/4" 7' 1" 8' 9" 10' 5" 12' 1"...

  • Page 16: Chapter 6 Dimensions

    6. DIMENSIONS Elbow Angle Measurements L=10 + (.873 x Deg.) 801A025 8011235 L=10 + (.8813 x Deg. 8021120 802A015 L=10 + (.8911 x Deg.) 804A014 8041124 Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 17: Chapter 7 Assembly

    Air System Set-Up Procedures 1. The air filter extension tube and housing are connected to the blower inlet by a compression coupler. For extended filter life, if the pneumatic system is being operated in extremely dirty conditions, a longer extension tube can be used between the blower inlet and the air filter. BE SURE the air filter is positioned so that routine inspection and service can be performed.
  • Page 18 7. ASSEMBLY See Figure 7D Place the matching set of V-belts on the pulleys. Tighten the belts by evenly turning the cap screws clockwise. Belts should have 3/8" deflection at ten pounds pressure per belt. (See Figure 7E). Figure 7E Figure 7D CAUTION Too much tension on belts will cause blower damage.
  • Page 19 7. ASSEMBLY 8. Using four (4) 5/16" x 3/4" flange head bolts, mount the motor to the airlock deck. Place the specified pulley on to the motor shaft and align to pulley on gearbox. (See Figure 7H). Figure 7I Figure 7H 9.

  • Page 20: Air System Control Box Definitions

    7. ASSEMBLY Air System Control Box Definitions 1. Air Pressure Gauge 6. Digital Amp Meter 2. Power “On” Indicator 7. Tripped Overload Light Indicator Light 3. Control Circuit Ready Indicator Light 4. Start/Stop Switch 8. 5 Amp Fuse 5. Air Pressure Limit 9.
  • Page 21 7. ASSEMBLY 1. Air Pressure Gauge: This gauge indicates the system air pressure. 2. Power-On Indicator Light: This lamp will light up when power is supplied to the control box. 3. Control Circuit Ready Indicator Light: This lamp will light up when the start button has been pushed and all control circuits are completed.
  • Page 22 7. ASSEMBLY Figure 7M Auto Remote Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 23: Chapter 8 O/L Chart

    4" & 5" Overload Set Chart SINGLE MOTOR 4" 700 10 Hp, 230V -1 Ph 4" 700 10 Hp, 230V - 3 Ph 4" 700 460V 10 Hp - 3 Ph 575V 4" 700 15 Hp, 230V - 1 Ph 4"...

  • Page 24: Chapter 9 Wiring

    9. WIRING Schematic - 230V-1PH Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 25: Schematic - 230V/460V/575V-3Ph

    9. WIRING Schematic - 230V/460V/575V-3PH Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 26: Schematic - Twin Air Systems

    9. WIRING Schematic - Twin Air Systems Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 27: Chapter 10 Operation And Management

    Control Box Operational Procedures Automatic operation using the Automatic Controller Unit tied to terminals one (1) and two (2). 1. Switch all circuit breakers to the “ON” position. 2. Place the Blower, Airlock and Auxiliary Control Switches in the “OFF” position. 3.

  • Page 28: Air System Operation Guidelines

    10. OPERATION AND MANAGEMENT Air System Operation Guidelines 1.Be aware of the quality of grain that is entering and leaving the air system. Grain damage can occur with any pneumatic system unless care is taken to adjust the velocity of the grain. This can be done by opening or closing the outlet gate valve on the blower outlet of the air system.
  • Page 29 10. OPERATION AND MANAGEMENT 5. The airlock is provided with a housing that incorporates grain shear protection to prevent grain damage. 6. GUIDELINES FOR OPERATION OF AIR SYSTEMS a. Grain in a pneumatic air system running at full capacity will move at about 60% of the air speed.

  • Page 30: Chapter 11 Hook-Up Diagrams

    11. HOOK-UP DIAGRAMS WIRING FOR A SURGE TANK HOOKED TO AN AIR SYSTEM The Air System will start when both P1 and P2 are closed. As it empties, P1 will open but will not stop the unit due to Auxiliary Contacts being closed. When P2 opens, the unit will stop. Note: Be sure the auxiliary switch is in the “AUTO”...
  • Page 31 NOTES Pneg-1563 4" & 5" Air Systems '07 Production...

  • Page 32: Chapter 12 Parts List

    12. PARTS LIST 1. Blower Outlet Parts 2. 4" (700) & 5" (1200) Standard Blower Parts 3. 4" & 5" Twin Blower Parts 4. 5" (1700) Hi-Capacity Blower Parts 5. 5" (1700) Twin Hi-Capacity Blower Parts 6. 4" & 5" Blower Filters 7.

  • Page 33: Blower Outlet Parts

    12. PARTS LIST Blower Outlet Parts Blower Outlet Parts 4" 5" 6" Ref # Part # Description PT1132 Gate Valve - 1-1/2"Npt 4FH0509 Pipe Nipple 1/4npt X 3 Galv Sch 40 4FH0971 Hose Barb 1/4 X 1/4 Mpt Brass 4FH0581 Pipe Tee - 1/4 Fpt Galv PT1127 Gauge - Oil Filled 0-15 PSI...

  • Page 34: 4" (700) & 5" (1200) Standard Blower Parts

    12. PARTS LIST 4" (700) & 5" (1200) Standard Blower Parts Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 35 12. PARTS LIST 4" (700) & 5" (1200) Standard Blower Parts 4" 5" Ref # Part # Description AS-0003 Blower Base Asy 4" & 5" AS-0108 Drv Guard Asy-4"& 5" STD Blower AS-0047 Motor MTG Plate Asy-4" Air Sys AS-0058 Motor MTG Plate Asy-5"...

  • Page 36: 4" & 5" Twin Blower Parts

    12. PARTS LIST 4" & 5" Twin Blower Parts Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 37 12. PARTS LIST 4" & 5" Twin Blower Parts Ref # Part # 4" Qty 5" Qty Description AS-0007 Blower Base Asy 4" & 5" Twin AS-0110 Drv Guard Asy-4"& 5" TWN Blower 8011266 Blower Sub-asy-4" & 5" Std DMC 8011266F Blower Sub-asy-4"...

  • Page 38: 5" (1700) Hi-Capacity Blower Parts

    12. PARTS LIST 5" (1700) Hi-Capacity Blower Parts Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 39 12. PARTS LIST 5" (1700) Hi-Capacity Blower Parts Ref # Part # Description AS-0003 Blower Base Asy 4" & 5" AS-0108 DRV Guard Asy-4"& 5" STD Blower CA-1059 Blower Sub-asy -5" HICAP DMC CA-1059F Blower Sub-asy-5" HICAP FFI AS-0058 Motor Mtg Plate Asy-5" Air Sys 802B006 Blower Gasket-5"...

  • Page 40: 5" (1700) Twin Hi-Capacity Blower Parts

    12. PARTS LIST 5" (1700) Twin Hi-Capacity Blower Parts Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 41 12. PARTS LIST 5" (1700) Twin Hi-Capacity Blower Parts Ref # Part # Description AS-0007 Blower Base Asy 4" & 5" Twin AS-0110 DRV Guard Asy-4"& 5" Twn Blower CA-1059 Blower Sub-Asy -5" HICAP DMC CA-1059F Blower Sub-Asy -5" HICAP FFI S-9067 Bolt Flngs 3/8-16 x 3/4 ZN GR5 S-968...

  • Page 42: 4" & 5" Blower Filters

    12. PARTS LIST 4" & 5" Blower Filters Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 43 12. PARTS LIST 4" & 5" Blower Filters Ref # Part # Description 8021224-RD Base-Prefilter, 5" Weldment-DMC 8021224-OR Base-Prefilter, 5" Weldment-FFI 801A104-RD Canister- Air Filter -16"-Red 801A104-OR Canister- Air Filter -16"-Orange 802A072-D Filter Base-5 Assembly-DMC 802A072-F Filter Base-5 Assembly-FFI 8021219-D Filter Canister-w/Inlet-Assembly Precleaner-DMC 8021219-F Filter Canister-w/Inlet-Assembly Precleaner-FFI...

  • Page 44: 4" & 5" Airlock Parts

    12. PARTS LIST 4" & 5" Airlock Parts Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 45 12. PARTS LIST 4" & 5" Airlock Parts Ref # Part # 4" Qty 5" Qty Description AS-0011 Airlock Base Asy-4" & 5" AS-0060 Airlock Sub-Asy-4" System DMC AS-0062 Airlock Sub-Asy-5" System DMC AS-0060F Airlock Sub-Asy-4" System FFI AS-0062F Airlock Sub-Asy-5" System FFI AS-0114 Gearbox Assembly-DMC AS-0114F...

  • Page 46: Airlock Inlet Transition Assembly

    12. PARTS LIST Airlock Inlet Transition Assembly Airlock Inlet Transition Assembly Ref # Part # Description AS-0077 Airlock Inlet Trans-RH & LH AS-0078 Airlock Trans-Front & Back S-9028 Screw, SMSAB 1/4-14 x 1/2 Hwh ZN S-8857 Bolt Flngs 1/4-20 x 1/2 ZN GR5 S-7215 Nut Flangwz 1/4-20 Zinc Installation of Airlock Transition to Dryer Discharge.

  • Page 47: Panel Module Assembly - Digital

    12. PARTS LIST Panel Module Assembly - Digital Panel Module Assembly - Digital Ref # Part # Description 8015075D-DC Decal - Transfer Panel W/digi amp 8015121D-DC Decal - Convey Air Panel W/digi amp 8015076D Module Control Panel - Digi Amp PT1125 Gauge- (Pressure) 2-1/2"15 PSI AS-0211A...

  • Page 48: Switch Panel Assembly - Standard

    12. PARTS LIST Switch Panel Assembly - Standard Switch Panel Assembly - Standard Ref # Part # Description AS-0294 Switch Panel - Standard 8015078-DC Decal - Standard Switch Panel AS-0365 Rocker Switch - Spdt (On-None-On) AS-0366 Rocker Switch - Spdt (On-Off-On) 2EL0618 Pushbutton Switch - Spst (Start) 2EL0619...

  • Page 49: Switch Panel Assembly - Twin

    12. PARTS LIST Switch Panel Assembly - Twin Switch Panel Assembly - Twin Ref # Part # Description AS-0309 Switch Panel - Twin 8015110-DC Decal - Twin Switch Panel AS-0365 Rocker Switch - Spdt (On-None-on) AS-0366 Rocker Switch - Spdt (On-Off-On) 2EL0618 Pushbutton Switch - Spst (Start) 2EL0619...

  • Page 50: Control Box Enclosure Parts

    12. PARTS LIST Control Box Enclosure parts Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 51 12. PARTS LIST Control Box Enclosure parts Std DMC Std FFI 1 Std DMC Std FFI 3 Twin Twin FFI Ref # Part # Description 1Ph Qty Ph Qty 3Ph Qty Ph Qty DMC Qty AS-0260 Control Box - Sub-Asy Air Sys Panel Module Asy W/digiamp AS-0326D Panel Module Asy W/digiamp...

  • Page 52: Standard Control Panel Assembly - 230V - 1 Phase

    12. PARTS LIST Standard Control Panel Assembly - 230V - 1 Phase Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 53 12. PARTS LIST Standard Control Panel Assembly - 230V - 1 Phase 10 Hp 15 Hp Ref # Part # Description AS-0258 Panel-Chassis 1 PH & Twin Air Sys DC-889 Dcl, Danger High Voltage All Pf AS-0264 Terminal Block 385a 600v 2 Pole 1:6 S-1158 Screw, TCSF #8-32 x 1/2 PHP ZN E160-1137...

  • Page 54: Standard Control Panel Assembly 10-30 Hp 230V - 3 Phase

    12. PARTS LIST Standard Control Panel Assembly 10-30 HP 230V - 3 Phase Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 55 12. PARTS LIST Standard Control Panel Assembly 10-30 HP 230V - 3 Phase 10 Hp 15 Hp 20 Hp 30 Hp Ref # Part # Description AS-0279 Panel-chassis 3 Ph Air Sys DC-889 Dcl, Danger High Voltage All Pf C-8018 Terminal Block 185A 600V 3 Pole 1:4 1EL0912 Terminal Block 385A 600V 3 Pole 1:6...

  • Page 56: Standard Control Panel Assembly 40 Hp 230V - 3 Phase

    12. PARTS LIST Standard Control Panel Assembly 40 HP 230V - 3 Phase Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 57 12. PARTS LIST Standard Control Panel Assembly 40 HP 230V - 3 Phase Ref # Part # Description AS-0279 Panel-Chassis 3 Ph Air Sys DC-889 Dcl, Danger High Voltage All Pf 1EL0912 Terminal Block 385A 600V 3 Pole 1:6 S-1158 Screw, TCSF #8-32 x 1/2 PHP ZN E160-1137 Lug Ground, #ta-2 (Csa)

  • Page 58: Standard Control Panel Assembly 10-40 Hp 460V - 575V 3 Phase

    12. PARTS LIST Standard Control Panel Assembly 10-40 HP 460V - 575V 3 Phase Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 59 12. PARTS LIST Standard Control Panel Assembly 10-40 HP 460V - 575V 3 Phase 15 Hp 20 Hp 30 Hp Ref # Part # 10 Hp Qty 40 Hp Qty Description AS-0279 Panel-chassis 3 Ph Air Sys DC-889 Dcl, Danger High Voltage All Pf C-8018 Terminal Block 185A 600V 3 Pole 1:4 S-1158...

  • Page 60: Twin Control Panel Assembly 230V - 1 Phase

    12. PARTS LIST Twin Control Panel Assembly 230V - 1 Phase Pneg-1563 4" & 5" Air Systems '07 Production...
  • Page 61 12. PARTS LIST Twin Control Panel Assembly 230V - 1 Phase 7.5 Hp 10 Hp 15 Hp Ref # Part # Description AS-0258 Panel-chassis 1 Ph & Twin Air Sys DC-889 Dcl,danger High Voltage All Pf AS-0264 Terminal Block 385A 600v 2 Pole 1:6 S-1158 Screw, TCSF #8-32 x 1/2 PHP ZN E160-1137...

  • Page 62: Chapter 13 Troubleshooting

    13. TROUBLESHOOTING Problem Solution 1. System Plugs Up 1. Check belt tension on air blower and tighten if loose. 2. Check air filter and clean out. Locate in a place where there is less dust. 3. Check tubing system for any obstructions. 4.
  • Page 63 13. TROUBLESHOOTING Problem Solution 4. Unit will not start, “ready light” is not 1. Check AC power supply. 2. Check control box fuses. 3. Thermal overload tripped (overload indicator is on). 4. Air pressure limit switch may be misadjusted (less than 5 PSI). If pressure switch is not reset, turn pressure adjustment clockwise until switch resets.

  • Page 64: Chapter 14 Couplings

    14. COUPLINGS How to Handle Handling Couplings 1. Couplings are shipped ready-to-install... do not disassemble. To prevent gasket from slipping out of proper position, always grasp coupling as shown in Figure 14A. This will save time by maintaining proper position of gasket and sleeve in relation to shell and flange. Installing Couplings 1.

  • Page 65: Chapter 15 Warranty

    Limited Warranty 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 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,...
  • Page 66 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 © 2009 by the GSI Group Printed in the USA...

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