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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-1355
Date: 03-29-07
PNEG-1355

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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-1355 Date: 03-29-07 PNEG-1355...
  • Page 2 PNEG-1355 4" & 5" Air Systems...

  • 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 ........................39 4" (700) & 5" (1200) Standard Blower Parts ..............40 4" & 5" Twin Blower Parts ....................42 5" (1700) Hi-Capacity Blower Parts .................44 5" (1700) Twin Hi-Capacity Blower Parts .................46 4" & 5" Blower Filters .......................48 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. Gloves Wear gloves to protect your hands from 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-995 DC-1386 N10080 DC-994 DC-995 PNEG-1355 4" & 5" Air Systems...

  • Page 11: Chapter 3 Maintenance

    Maintenance Schedule Initial Start-Up *2004 & Later Production - Use MS5389. Older units use non-detergent 50W. 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.

  • 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 NOTES PNEG-1355 4" & 5" Air Systems...

  • Page 16: Air System Tubing Dimensions

    5. INSTALLATION Air System Tubing Dimensions Figure 5B PNEG-1355 4" & 5" Air Systems...
  • Page 17 5. INSTALLATION PNEG-1355 4" & 5" Air Systems...

  • Page 18: Chapter 6 Dimensions

    6. DIMENSIONS Elbow Angle Measurements L=10 + (.873 x Deg.) 801A025 8011235 L=10 + (.8813 x Deg.) 802A015 8021120 L=10 + (.8911 x Deg.) 804A014 8041124 PNEG-1355 4" & 5" Air Systems...

  • Page 19: 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 20 7. ASSEMBLY 4. Place the specified pulley onto the motor and align it with the blower pulley. (See Figure 7C). Figure 7C 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.
  • Page 21 7. ASSEMBLY Figure 7E CAUTION Too much tension on belts will cause blower damage. 6. Keeping the motor in proper alignment is necessary and can be accomplished by using an open-end wrench to turn the nut on the take-up bolt closest to the rear of the motor. This nut is located behind the flange of the blower base.
  • Page 22 7. ASSEMBLY 7. The oil level should be at the center of the sight glass on the blower. Add part number MS5389 if required. DO Not Operate Blower Until Correct Oil Level is Indicated! The 4" roots blower has sight glasses on both ends. Be sure oil levels are indicated on both sight glasses.
  • Page 23 7. ASSEMBLY 9. Next, place the A-24 belt onto the pulleys. See Figure 7I Tighten the belt to its proper tension of 3/8" deflection at ten pounds of pressure by pulling motor away from gearbox. Tighten the four 5/16" flange bolts on the motor base. Replace the belt shield. Figure 7I 10.
  • Page 24 7. ASSEMBLY 11. Remove 1/4" pipe plug in gate valve pipe. Install gauge assembly and attach air hose. (See Figure 7K) Figure 7K THE SET-UP OF THE PNEUMATIC AIR SYSTEM IS NOW COMPLETE. PNEG-1355 4" & 5" Air Systems...

  • Page 25: 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 8. 5 Amp Fuse 5. Air Pressure Limit 9.
  • Page 26 7. ASSEMBLY 7. Tripped Overload Indicator Light: This lamp will light up when any of the motor thermal overloads in the control box has tripped. The overloads for all three circuits (Aux, Airlock, and Blower) must have thermal overloads installed to operate the system. See Thermal Unit chart Drawing on page 8.

  • Page 27: Chapter 8 O/L Thermals

    Air System Control Box - Thermal Unit Chart SINGLE MOTOR 4" 700 10HP, 230V, 1PH 4" 700 10HP, 230V, 3PH 4" 700 10HP, 440V, 3PH 4" 700 15HP, 230V, 1PH 4" 700 15HP, 230V, 3PH 4" 700 15HP, 440V, 3PH 4"...

  • Page 28: Chapter 9 Wiring

    9. WIRING Standard Schematic With Digital Amp Meter PNEG-1355 4" & 5" Air Systems...

  • Page 29: Standard Schematic With Analog Amp Meter Using 2El0273 Control Relay

    9. WIRING Standard Schematic With Analog Amp Meter Using 2EL0273 Control Relay PNEG-1355 4" & 5" Air Systems...

  • Page 30: Schematic With Analog Amp Meter Using Hf-7203 Control Relay

    9. WIRING Schematic With Analog Amp Meter Using HF-7203 Control Relay PNEG-1355 4" & 5" Air Systems...

  • Page 31: Twin Schematic With Digital Amp Meter

    9. WIRING Twin Schematic With Digital Amp Meter PNEG-1355 4" & 5" Air Systems...

  • Page 32: Twin Schematic With Analog Amp Meter Using 2El0273 Control Relay

    9. WIRING Twin Schematic With Analog Amp Meter Using 2EL0273 Control Relay PNEG-1355 4" & 5" Air Systems...

  • Page 33: Twin Schematic With Analog Amp Meter Using Hf-7203 Control Relay

    9. WIRING Twin Schematic With Analog Amp Meter Using HF-7203 Control Relay PNEG-1355 4" & 5" Air Systems...

  • Page 34: Chapter 10 Operation And Management

    10. OPERATION AND MANAGEMENT Control Box Operational Procedures Automatic operation using the Automatic Controller Unit tied to terminals one (1) and two (2). 1. Place the Blower, Airlock and Auxiliary Control Switches in the “Off” position. 2. Place the Air Pressure Limit Control Switch in the “On” position (unit will stop when the air pressure reaches 10 PSI).

  • Page 35: 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 36 10. OPERATION AND MANAGEMENT 4. The air filter element should be inspected daily and cleaned when required. Both the poly foam pre-filter and the filter element can be cleaned by blowing air through them or washing them with mild detergent and water. A restricted air filter will cause a system to become plugged.
  • Page 37 10. OPERATION AND MANAGEMENT 8. RECOMMENDATIONS FOR OFF-SEASON STORAGE The blower and airlock have precision machined components and must be protected to prevent corrosion and rust from forming on the blower lobes and airlock vanes. These parts should be coated with motor oil after each drying season. (Spray lubricants such as WD-40 do not usually provide adequate protection.) Both the airlock and blower assemblies should be carefully protected from the weather and the piping system disconnected from the blower and airlock.

  • Page 38: Chapter 11 Hook-Up Diagrams

    11. HOOK-UP DIAGRAMS WIRING FOR A SURGE TANK HOOKED TO A TRANS-FER 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 4R4 being closed. When P2 opens, the unit will stop. P1 and P2 are Pressure Switches.
  • Page 39 1. 4" (700) & 5" (1200) Standard Blower Parts 2. 4" & 5" Twin Blower Parts 3. 5" (1700) Hi-Capacity Blower Parts 4. 5" (1700) Twin Hi-Capacity Blower Parts 5. 4" & 5" Blower Filters 6. 4" & 5" Airlock Parts 7.

  • Page 40: Chapter 12 Parts List

    12. PARTS LIST 4" (700) & 5" (1200) Standard Blower Parts PNEG-1355 4" & 5" Air Systems...
  • Page 41 12. PARTS LIST 4" (700) & 5" (1200) Standard Blower Parts Ref # Part # 4" Qty 5" Qty 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 42: 4" & 5" Twin Blower Parts

    12. PARTS LIST 4" & 5" Twin Blower Parts PNEG-1355 4" & 5" Air Systems...
  • Page 43 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 44: 5" (1700) Hi-Capacity Blower Parts

    12. PARTS LIST 5" (1700) Hi-Capacity Blower Parts PNEG-1355 4" & 5" Air Systems...
  • Page 45 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 46: 5" (1700) Twin Hi-Capacity Blower Parts

    12. PARTS LIST 5" (1700) Twin Hi-Capacity Blower Parts PNEG-1355 4" & 5" Air Systems...
  • Page 47 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 48: 4" & 5" Blower Filters

    12. PARTS LIST 4" & 5" Blower Filters PNEG-1355 4" & 5" Air Systems...
  • Page 49 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 801A154...

  • Page 50: 4" & 5" Airlock Parts

    12. PARTS LIST 4" & 5" Airlock Parts PNEG-1355 4" & 5" Air Systems...
  • Page 51 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 52: Airlock Inlet Transition Assembly

    12. PARTS LIST Airlock Inlet Transition Assembly PNEG-1355 4" & 5" Air Systems...
  • Page 53 12. PARTS LIST 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 54: Panel Module Assembly - Digital

    12. PARTS LIST Panel Module Assembly - Digital Panel Module Assembly - Digital Ref # Part # Description 8015075D Panel-W/Silkscreen Digi amp DMC 8015121D Panel-W/Silkscreen Digi amp FFI PT1125 Gauge- (Pressure) 2-1/2" 15 PSI 4FH0452 Fit-elbow,street(90) 1/4 NPT 4FH1122 Fit-hose Barb,1/4 x 1/4 Brass AS-0211A Digital Amp Meter Asy W/Jumper TFH-2021...

  • Page 55: Panel Module Assembly - Analog

    12. PARTS LIST Panel Module Assembly - Analog Panel Module Assembly - Analog Ref # Part # Description 8015075 Single Main Panel Deadfront-DMC 8015121 Single Main Panel Deadfront-FFI PT1125 Gauge- (Pressure) 2-1/2" 15 PSI 2EL0290 Amp Meter Panel 0-150 Amp TFH-2021 Light Red Neon Spade Term 125 VAC 1EL0826...

  • Page 56: Switch Panel Assembly - Standard

    12. PARTS LIST Switch Panel Assembly - Standard Switch Panel Assembly - Standard Ref # Part # Description 8015078 Switch Panel-Standard 2EL0668 Lever Switch-SPDT (ON-OFF-ON) 2EL0659 Lever Switch-SPDT (ON-NONE-ON) 2EL0618 Pushbutton Switch-SPST (START) 2EL0619 Pushbutton Switch-SPST (STOP) PNEG-1355 4" & 5" Air Systems...

  • Page 57: Switch Panel Assembly - Twin

    12. PARTS LIST Switch Panel Assembly - Twin Switch Panel Assembly - Twin Ref # Part # Description 8015110 Switch Panel-Twin 2EL0659 Lever Switch-Spdt (ON-NONE-ON) 2EL0618 Pushbutton Switch-SPST (START) 2EL0619 Pushbutton Switch-SPST (STOP) 2EL0668 Lever Switch-SPDT (ON-OFF-ON) PNEG-1355 4" & 5" Air Systems...

  • Page 58: Standard Control Panel Assembly - 230 V 10-30 Hp

    12. PARTS LIST Standard Control Panel Assembly - 230 V 10-30 HP PNEG-1355 4" & 5" Air Systems...
  • Page 59 12. PARTS LIST Standard Control Panel Assembly - 230 V 10-30 HP Analog Digital Ref # Part # Description 8015079 Air Sys-control Panel (SNGL) 2EL0281 Relay THRML Oveload 26 Amp S-1158 Screw TCSF #8-32 x 1/2 PHP Zn 2EL0243 40A Contactor-Magnetic (CSA) 2EL0648 Contact- Auxiliary Motor Contactor 2EL0282...

  • Page 60: Standard Control Panel Assembly - 230 V 10-30 Hp Used In 8015071 Control Box (Csa Listed)

    12. PARTS LIST Standard Control Panel Assembly - 230 V 10-30 HP Used In 8015071 Control Box (CSA Listed) PNEG-1355 4" & 5" Air Systems...
  • Page 61 12. PARTS LIST Standard Control Panel Assembly - 230 V 10-30 HP Used in 8015071 Control Box (CSA Listed) Ref # Part # New CSA Design Description 8015079 Air Sys-control Panel (SNGL) 2EL0281 Relay THRML Oveload 26 Amp S-1158 Screw TCSF #8-32 x 1/2 PHP Zn 2EL0243 40A Contactor-Magnetic (CSA) 2EL0648...

  • Page 62: Standard Control Panel Assembly - 230 V 40 Hp

    12. PARTS LIST Standard Control Panel Assembly - 230 V 40 HP PNEG-1355 4" & 5" Air Systems...
  • Page 63 12. PARTS LIST Standard Control Panel Assembly - 230 V 40 HP Analog Digital Ref # Part # Description 8015079 Air Sys-Control Panel (SNGL) 2EL0281 Relay THRML Oveload 26 Amp S-1158 Screw TCSF #8-32 x 1/2 PHP Zn 2EL0243 40A Contactor-Magnetic (CSA) 2EL0648 Contact-Auxiliary Motor Contactor 1773...

  • Page 64: Twin Control Panel Assembly - 230 V 7-15 Hp

    12. PARTS LIST Twin Control Panel Assembly - 230 V 7-15 HP PNEG-1355 4" & 5" Air Systems...
  • Page 65 12. PARTS LIST Twin Control Panel Assembly - 230 V 7-15 HP Analog Digital Ref # Part # Description 8015111 Air Sys-Control Panel (Twin) 2EL0243 40a Contactor-Magnetic (CSA) 2EL0648 Contact-Auxiliary Motor Contactor S-1158 Screw TCSF #8-32 x 1/2 PHP Zn 2EL0281 Relay THRML Oveload 26 Amp 802L006...

  • Page 66: Twin Control Panel Assembly - 230 V 7-15 Hp Used In 8015114 Control Box (Csa Listed)

    12. PARTS LIST Twin Control Panel Assembly - 230 V 7-15 HP Used in 8015114 Control Box (CSA Listed) PNEG-1355 4" & 5" Air Systems...
  • Page 67 12. PARTS LIST Twin Control Panel Assembly - 230 V 7-15 HP Used in 8015114 Control Box (CSA Listed) Ref # Part # New CSA Design Qty Description 8015111 Air Sys-Control Panel (Twin) 2EL0243 40A Contactor-Magnetic (CSA) 2EL0648 Contact-Auxiliary Motor Contactor S-1158 Screw TCSF #8-32 x 1/2 PHP Zn 2EL0281...

  • Page 68: Standard Control Panel Assembly - 460 V 10 - 40 Hp

    12. PARTS LIST Standard Control Panel Assembly - 460 V 10 - 40 HP PNEG-1355 4" & 5" Air Systems...
  • Page 69 12. PARTS LIST Standard Control Panel Assembly - 230 V 10-40 HP Analog Digital Ref # Part # Description 8015079 Air Sys-Control Panel (SNGL) 2EL0281 Relay Thermal Oveload 26 Amp S-1158 Screw TCSF #8-32 x 1/2 PHP Zn 2EL0243 40A Contactor-Magnetic (CSA) 2EL0648 Contact-Auxiliary Motor Contactor 2EL0282...

  • Page 70: Control Panel Assembly - 460 V 10-40 Hp Used In 8015072 Control Box (Csa Listed)

    12. PARTS LIST Control Panel Assembly - 460 V 10-40 HP Used In 8015072 Control Box (CSA Listed) PNEG-1355 4" & 5" Air Systems...
  • Page 71 12. PARTS LIST Control Panel Assembly - 460 V 10 - 40 HP Used In 8015072 Control Box (CSA Listed) Ref # Part # New CSA Design Qty Description 8015079 Air Sys-Control Panel (SNGL) 2EL0281 Relay THRML Oveload 26 Amp S-1158 Screw TCSF #8-32 x 1/2 PHP Zn 2EL0243...

  • Page 72: 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 73 13. TROUBLESHOOTING Problem Solution 4. Unit will not start, “ready light” is 1. Check AC power supply. not on. 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 74: 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 75: Chapter 15 Warranty

    WARRANTY THE GSI GROUP, INC. (GSI) WARRANTS ALL PRODUCTS WHICH IT MANUFACTURES TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF 12 MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER. THE PURCHASER’S SOLE REMEDY AND GSI’S ONLY OBLIGATION SHALL BE TO REPAIR OR REPLACE, AT GSI’S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI’S...
  • Page 76 Authorities having jurisdiction should be consulted before installations are made. GSI Group, Inc. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 Internet: http://www.grainsystems.com Copyright © 2007 by the GSI Group Printed in the USA...

This manual is also suitable for:

1200 bu/hr1700 bu/hr

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