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GSI Group PNEG-369 Owner's Manual

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  • Page 3 OUNDATION EQUIREMENTS IRCULAR OUNDATION CTAGONAL OUNDATION ROST NCHOR AYOUT ARDWARE OCATION CCESSORIES MPORTANT & S IDEWALL TIFFENER AUGES UTSIDE TIFFENERS TIFFENER TARTING OCATION & L TIFFENER NSTALLATION OCATION OLTING EQUIREMENTS & S TIFFENER OCATIONS IDEWALL ONSTRUCTION NSTRUCTIONS & B TIFFENER RACKET NSTALLATION "C"...

  • Page 4: Roof Damage Warning And Disclaimer

    Avoid any alterations to the equipment. Such alter- trical power. ations may produce a very dangerous situation, The principal concern of the GSI Group, Inc. where serious injury or death may occur. ("GSI") is your safety and the safety of others asso- ciated with grain handling equipment.
  • Page 5 The GSI Group, Inc. recom- mends contacting your local power company, and having a representative survey your instal- lation so the wiring is compat- ible with their system, and ad- equate power is supplied to your unit. Safety decals should be read and understood by all people in the grain handling area.
  • Page 6 READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE Use Caution in the SAVE FOR FUTURE REFERENCE Operation of this 1. Read and understand the operating manual before trying to operate the Equipment dryer. The design and manufacture of this dryer is directed toward operator 2.
  • Page 7 Date Employer’s Signature Employee Employees working on or around grain drying equipment must read this manual and sign-off on this sheet.

  • Page 8: Power Supply

    Power Supply An adequate power supply and proper wiring are important the ignition system. The ground rod must be in factors for maximum performance and long life of the accordance with local requirements. dryer. Electrical service must be adequate enough to prevent low voltage damage to motors and control circuits Proper Installation of Ground Rod (see Electrical Load Information on page 40).
  • Page 9 Splice connections are figured for the top of the stiffener splices Per Splice 18ga, 16 ga S-7927 3/8" X 1" Hex Flanged Splice Bolting S-845 5/16" Washer S-456 3/8" Hex Nuts (2 Stiffeners per sheet) Stiffener to Sidewall Per Sheet [(22) S-275 per sheet] Bolting S-275...
  • Page 10 Refer to stiffe ner sheets for stiffener to sidewall hardware usage. 20ga to 15ga 5/16" x 3/4" Bin Bolt S-275 5/16" Hex Nuts S-396 Caulking (24' Roll) S-4458 14ga to 13a. S-275 5/16" x 3/4" Bin Bolt S-396 5/16" Hex Nuts S-4458 Caulking (24' Roll) Roof Hardware (inserted in sidewall hardware)

  • Page 11: Specifications

    FOUNDATION SPECIFICATIONS SHALL CONSTRUED RECOMMENDATIONS ONLY. BECAUSE OF THE MANY VARIABLE CONDITIONS IN AN ACTUAL INSTALLATION, GRAIN SYSTEMS, INC. ASSUMES NO LIABILITY FOR RESULTS ARISING FROM THE USE OF SUCH RECOMMENDATIONS. Site Preparation Foundation Radius Spike Two Feet 2 x 4 Center Stake Pointed Stake Foundation Line Selecting The Proper Site...
  • Page 12 Footing Trench Carpenter's Level PREPARE THE FOUNDATION Having scribed the diameter of your foundation, proceed by digging the footing of the foundation. This consists of a large circular trench dug just inside the foundation line. (Refer to foundation details for necessary information.) Once the footing has been dug, you are ready to build the forms.
  • Page 13 There are two styles of foundation forms commonly used. The first is the circular form depicted in Figure #2. The second style can be made of 2" x 8" boards set into a square with corners blocked off to form an octagon. (See Figure #3 below.) This eight sided form will approximate a circle and can be constructed quite easily.
  • Page 14 NOTES: • Foundation site should be well drained and free of vegetation or debris. • Foundation design is based on a minimum soil bearing capacity of 3,000 lb/ft . If soil bearing capacity is in doubt, contact a local soil testing engineer. •...
  • Page 15 Refer to following diagram for proper bolt layout. Having poured and leveled the concrete, use the center stake and straight 2" x 4" again to find bolt circle radius for the outside stiffener bolts. Select a starting point and stretch a pre-measured chord along the imaginary circle formed by the bolt circle radius.
  • Page 16 CAUTION: UNDER NO CONDITION NOTE: Grade 2 bolts are SHALL ANY OTHER BOLTS BE designated with a plain head. SUBSTITUTED FOR THOSE SUPPLIED BY GRAIN SYSTEMS, INC. NOTE: Grade 5 bolts are designated by 3 slash marks on the head. IMPORTANT: HARDWARE USAGE All 5/16"...

  • Page 17: Side View

    Refer to Top Dry Tank Bolting Requirements for Complete Bolt Usage .950" Top View .750" .3125" x .750" pre-assembled with a steel backed neoprene washer. S-275 Side View Grade 5 This bolt is used to connect horizontal and vertical seams for 13 gage and thinner sidewall sheets to each other, and to bolt the stiffeners to the sidewall sheets.
  • Page 18 Refer to Top Dry Tank Bolting Requirements for Complete Bolt Usage 1.377" Top View 1.000" .375" x 1.000" hex flanged head without a plastic sealing S-7927 washer. Side View Grade 8 Grade 8.2 This bolt is used to splice the stiffeners together on the flanges. A steel flat washer is used on the nut side of the connection.
  • Page 19 Below is a typical Top Dry bin layout showing suggested locations of Top Dry Accessories. When locating the manway be sure the outside ladder will not interfere with other accessories below. Roof vents should be spaced evenly around the roof. (Quantity will vary with individual systems.) NOTE: The Top Dry system should be provided with a dependable equipment ground.

  • Page 20: Very Important

    VERY IMPORTANT! DC-1174 (Top Decal) Top of Sheet Horizontal seam hole locations determine top and bottom of sheet. Sheet shown as viewed from the inside of bin. Bottom of Sheet All 4.00" corrugated sidewall sheets must be placed correctly. All 4.00" corrugated sidewall sheets have a top and bottom! Failure to observe this will not allow the door to fit properly.
  • Page 21 Door locations are shown by the underlined sidewall gauges. Actual gauge of the access door sheet located just below the Top Dry floor is in parentheses. Top Dry Bin Sidewall Gauges TDMS24-5 20 20 (16) TDMS24-6 20 20 20 (16) TDMS24-7 20 20 20 20 (16)
  • Page 22 • The XX in the part numbers at the bottom will identify the Stiffener's gauge Example: FC-4205714 is a 2-Ring Standard Stiffener 14 Gauge. Stiffener Overall Color Description Part No. Length Code 2-Ring 10 Ga. (Base) FC-4207210 94 27/32" White 2-Ring 12 Ga.
  • Page 23 TOP STIFFENER STARTING LOCATION Refer to Figure #10, for proper location of top stiffeners. On the overlap of the stiffeners, and on the splice, use 3/8" x 1" hex bolts, a washer on thee nut side connection. Refer to the stiffener layout, Figure #8, for stiffener usage.
  • Page 24 When installing bottom stiffeners, you may find that in some cases the stiffener with base plate attached will not rest on the foundation (due to unlevel concrete, etc.) Shim plates have been furnished and should be used to fill opening between base plate and concrete. IMPORTANT: If shim plates are not used where required, the downward pressure of the stiffeners will not be transferred directly to the foundation, and bin failure could result.
  • Page 25 BOLTING REQUIREMENTS • 2 STIFFENERS PER SIDEWALL SHEET Sidewall Horizontal Vertical Stiffener Overlap Gauge Seam Seam To Sidewall Seam 17 Thru 20 5/16" x 3/4" 5/16" x 3/4" 5/16" x 3/4" 5/16" x 3/4" [10] [42] [20] All bolts are standard bin bolts with neoprene washers. For horizontal and vertical seam bolts, the bolt head and neoprene washers are on the outside of the bin.
  • Page 26 STIFFENER & SEAM LOCATIONS Even Ring Bins Odd Ring Bins Horizontal Seam Horizontal Seam Horizontal Seam Horizontal Seam Horizontal Seam Horizontal Seam 2 stiffeners per sidewall sheet Top Dry stiffener starting location -18' to 36' 4" corrugation stiffener only...
  • Page 27 Note: The rope caulking is installed before each sheet is as- sembled. Apply rope caulking between the last vertical row of GAUGE COLOR CODE bolts and edge of outside sheet. There is sufficient caulking for White all vertical seams on storage and drying bins. Wipe sheet clean where caulking is to be applied.
  • Page 28 Right Left Sidewall Sidewall Concrete Foundation Using correct size bin bolts throughout, begin assembling sidewall sheets end to end (overlapping the same way throughout) until the ring is complete. All body sheet bolts are to be installed with the bolt head and its neoprene washer to the outside and the nut on the inside.
  • Page 29 Install the stiffeners on the outside of the bin (as shown in Figure #12) and the wall brackets on the inside of the bin. The wall brackets are to be positioned with the bracket's top hole matching the first hole up from the horizontal seam (not counting the horizontal seam).
  • Page 30 Fasten the rolled "C" eave members to the wall brackets in the upper 2 holes of the top set of three (3) holes leaving the bolts loose. Install the splice plates at the rolled "C" eave member seams using 3/8" x 1" flanged hex bolts and nuts. Tighten all bolts.
  • Page 31 Add channel braces and brace plates to center collar as shown using 3/8" x 1" bolts and nuts. (Do not attach cross channel until floor is done.) TD-100460 Channel Brace Plate TD-100459 Channel Brace TD-100004 Center Collar Cross TD-100630 Channel Center Collar (Don't install until floor is completed)
  • Page 32 RAFTER INSTALLATION & FLOOR SUPPORT ANGLE ATTACHMENT When installing the rafters, set the lower clip end on the "C" eave member. Leave the bolts to the center collar and the eave member loose until all rafters are in place. Use 3/8" x 1" hex bolts and nuts to connect the center collar and eave member to three (3) rafters at 90 degrees to each other.
  • Page 33 SPECIAL ANGLE PURLIN ASSEMBLY Where two rafters face the same direction use 5/16" x 3/4" bin bolts and nuts with the three bent edges facing toward the sidewall, the longest edge on top. TD-100782 Special Bay Purlin Bolt purlins to rafters (as shown in the photo) in the 4th hole counting up from the sidewall. TD-100782 Special Bay Purlin TD-100779...
  • Page 34 Bolt the long side of the hangers to the endmost slots of the top plate (TD-100665) as shown below. Hold the top plate up under the bottom flange of the "C" channel in front of the fan opening. Mark and drill four 3/8"...
  • Page 35 Attach front plate to the top plate with four (4) 1/4" x 1" self-drilling screws. Bolt the side brackets to the front plate slot with the angle outward. field drill two (2) holes (on inside corrugation hills) through the sidewall and install 5/16" x 3/4" bin bolts and nuts. Position the side plates on each side with the angle outward and fasten in place using six (6) 1/4"...
  • Page 36 Pre-assemble the dump hoppers, dump brackets, and flashing angles to the floor sheets. Place a dump hopper under the floor sheet and align it with the pre-punched large hole. Place a flashing angle on top of the sheet across the outer edge of the hopper entrance with the interior of the angle facing the sidewall. Screw down through the angle, sheet, and hopper with 5/16"...
  • Page 37 Install the leveling band posts on the floor as shown. The third and eighth holes in the floor sheet indicate the location of the leveling band posts. Attach posts with 5/16" x 1.1/4" bin bolts (S-277). The third hole from the bottom of the sheet, there will be 7 posts (1 every third sheet, except the last bay will cover five sheets).
  • Page 38 Install the eave flashing bolts (5/16" x 1.1/4") through the sidewall and tighten first nut. Note at the vertical sidewall seams, one bolt is turned around to avoid interference with eave flashing (refer to photo). FLASHING BOLT INSTALLATION Left bolt on the each vertical sidewall seam level with the eave flashing bolts (as viewed from inside the bin) is to be installed bolt in, nut out, as shown in...
  • Page 39 DISCHARGE PLATE INSTALLATION Install the discharge plate assemblies over the flashing with a fender washer and nuts letting the bottom bracket rest against the flashing. Screw the discharge plate together where they overlap with #10 self-drilling screws (S-280). 5/16" x 1.1/4" Bin Fender Washer TD-100648 Bolts with nuts...
  • Page 40 The flashing splice pieces can now be attached to the eave flashing to seal around the rib of the floor sheet as shown with (S-280) #10 self-drilling screws. Top Ring TD-100649 TD-100648 Eave Flashing Eave Flashing Splice (as viewed from inside the bin) #10 Self-drilling Screws Flashing Splice (S-280)
  • Page 41 Bolt the sections together to form perforated cone as shown below. Use 1/4" x 5/8" bolts and nuts to attach sections together. Flat Overhead View Formed Overhead View TD-100219 Perforated Cone Section (6 Required) Side Formed View 1/4" x 5/8" Bolts & Nuts Center Cone Assembly Install cone over the center collar.

  • Page 42: Special Instructions

    SPECIAL INSTRUCTIONS It is now time to assemble the roof. When starting, align manway and ladder such that it coordinates with the other accessories and does not interfere. The roof is assembled according to the instructions in the roof hardware box, WITH THE FOLLOWING EXCEPTIONS: 1.
  • Page 43 SPECIAL INSTRUCTIONS It is now time to assemble the roof. The roof is assembled according to the instructions in the roof hardware box, WITH THE FOLLOWING EXCEPTIONS: 1. Locate eave clips so that a roof sheet will be centered over sidewall ladder. 2.
  • Page 44 LEVELING BAND LOCATION Position leveling bands as shown in the drawings below. Use (2) 5/16" x 3/4" bin bolts to attach bands to posts. Also use 5/16" x 3/4" bin bolts to to join band sections. Note that band sections connect to each other only at endmost holes until completing the circle where an overlap may occur.
  • Page 45 Position the pulley assembly to the cross angle in the middle of the center collar assembly. Use a 3/8" x 1" hex head cap bolt to fasten assembly to the cross angle. Position the pulley in the direction of the desired winch location on the sidewall.
  • Page 46 Attach all 21 dump chute chains directly to the lift plate as shown in diagram below. Install all chains using "S" hooks (S-4692) to attach the chains to the dump chutes and lift plates. Keep excess chain at the lift plate. Adjust the chains until the chutes are approximately level when the lift plate is in the closed (up) position.
  • Page 47 Complete erection of bin. Install winch as shown using 5/16" x 3/4" bin bolts to attach to the sidewall. The cable clamps from either side of the pulley on the cross channel should be removed and the dump chutes pulled tightly shut.
  • Page 48 24" thru 36" Fans TD-100680 36" Fan Entrance Sheet TD-100099 Fan Adapter (28") TD-100537 Deflector (36" Fan Only) TD-100206 Fan Adapter-Blank TD-100098 Fan Adapter (24") 42" Fans 42" - TD-100681 Fan Entrance Sheet 42" - TD100523 Transition...
  • Page 49 **3/8" WASHERS ACD-4515 (2) (USE AS NEEDED) ACD-4510 (2) 3/8" X 1.1/2" FULL THREADS ACD-4514 3/8" X 1" BOLTS DOOR COVER INNER DOOR ACD- ACD-4504 4508 S-3867 (2) ACD-4513 ACD-4509 5/16" X 3/4" BOLT & #10 SCREWS ACCESS DOOR WELDMENT **THE QUANTITY OF 3/8"...
  • Page 50 NOTE: The number of lifting jacks required is best determined by personal experience. Factors such as bin size, soil compaction, wind velocity, jack design, etc., are all to be considered when deciding how many to use. If in doubt, use one jack on every other stiffener. GSI recommends heavy duty jacks rated at 6,000 lbs. or more. TD-100724 Lifting jack bracket...
  • Page 51 DETAILED LAYOUT FOR PROPER LOCATION OF PLATFORMS Outside Ladder 12" 12" TDP-5008 Sidewall Brace 56.1/2" TD-100685 TD-100686 Large Platform 12.1/8" Small Platform Vertical Support Vertical Support Inside Ladder Small Platform Large Platform Access Door Platform (Optional) (Optional)
  • Page 52 TDP-5012 Before assembly of any platform, read the entire instructions to assure proper placement and assembly. Refer to Figure #46 for proper location of access door platform. Begin by assembling the access door platform support frame using 5/16" x 3/4" truss head bolts and nuts. When attaching platform vertical support to bin sidewall field drill (16) 3/8"...
  • Page 53 For 36" Fans and Smaller or with #1 fan when two 36" or smaller fans are installed Before assembling any platform, read all of the instructions first to assure proper placement and assembly. Refer to Figure #43 for proper location of small platform. Begin by assembling the small platform support frame using 3/8"...
  • Page 54 SMALL PLATFORM ASSEMBLY (CONT.) 36" Fans and Smaller TD-100092 Position the vertical support to the existing sidewall stiffeners as shown in Figure #46 and double nut with 5/16" nuts. When bolting stiffener to sidewall at locations where platform supports are to be attached, use (25) 5/16"...
  • Page 55 For 42" Fan Before assembly of any platform, read the entire instructions to assure proper placement and assembly. Refer to Figure #43 for proper location of large platform. Begin by assembling the large platform support frame using 7/16" x 1" bolts on all connections. Use 5/16" x 1.1/4" bin bolt to attach the platform vertical supports to the sidewall stiffeners.
  • Page 56 LARGE PLATFORM ASSEMBLY (CONT.) (FOR 1 FAN SYSTEMS OR #2 FAN ON 2 FAN SYSTEMS) Position the vertical support to the existing sidewall stiffeners as shown in Figure #46 and double nut with 5/16" nuts. When bolting stiffener to sidewall at locations where platform supports are to be attached, use (25) 5/16"...
  • Page 57 (For use with stairs) TDP-5013 Before assembly of any platform, read the entire instructions to assure proper placement and assembly. Refer to Figure #46 for proper location of cross over platform. Begin by assembling the cross over platform support frame using 5/16" x 3/4" truss head bolts and nuts. When attaching platform vertical support to bin sidewall field drill (16) 3/8"...
  • Page 58 Drill (6) 3/8" diameter holes equally spaced as shown above for top band clips. Attach clips using 5/16" x 3/4" bin bolts. Add perforated band sections. Note that these do not attach to the leveling bands but hang down on the inside of the top inner leveling band. Measure down 25.1/4"...
  • Page 59 OPTIONAL ROTARY SWITCH ROOF LOCATIONS Fill Spout Optional High or Low Optional High or Low Limit Rotary Switch Limit Rotary Switch Overhead View of optional Optional Rotary Switch rotary Switch Locations Drill 2" diameter holes through roof panels at locations shown on previous page. Use a mounting plate as a pattern and drill (4) 3/8"...
  • Page 60 INSTALLATION OF ROOF-MOUNTED LEVEL SWITCH Drill 2" diameter holes through roof panels at locations shown on previous page. Use a mounting plate as a pattern and drill (4) 3/8" holes through roof panels at each switch location so the plate can be bolted to the roof. Attach flex-coupling to the power-pak and install roll pin.
  • Page 61 INSTALLATION OF WALL-MOUNTED ROTARY SWITCHES Note: Wall mounted switch must be located at least 3' below the fan opening. Drill 2" hole through wall 3' below the upper fan and heating unit(s). IF BIN IS 2.66" corrugation, hole should be centered on outside hill (see Figure #54 below) IF BIN IS 4.00" corrugation, hole should be centered on outside valley.
  • Page 62 ASSEMBLY OF HIGH/LOW LIMIT ROTARY SWITCHES Low Limit Rotary Switch TAF-6100 High Limit Rotary Switch TAF-6103 Part No. Description Quantity Weight TD-100076 Rotary Switch Power-Pak 3.50 TD-100629 Roof Mount Coupling Weldment 2.14 TD-100075 Flex-Coupling 0.50 S-7241 1/8" x 1.1/4" Cotter Pin 0.02 TAF-6085 1-Vane Paddle...
  • Page 63 BEFORE CUTTING THE OPENING CHECK THAT TR-4734 IS THE TRANSITION THAT WAS ORDERED. When installing the GSI aeration transition, it will be necessary to field cut a hole into the bottom sidewall ring (usually straight across from the unload auger). Refer to diagram for proper dimensions of cutout. The base angle will also need to be cut at entrance collar cutout.
  • Page 64 Sizing angle is to be installed on inside of bin sidewall sheet as shown. The flanges on transition top are to go on the out- Part Number Description side of transition TR-4724-1 Transition side sides. The flanges TR-4724-2 Transition side on transition bot- TR-4767 Transition faceplate...
  • Page 65 TWO RING DOOR INSTALLATION & ACCESSORIES Before starting to install, be sure the correct door has been received. 4.00" Bin Corrugation WD-6133 24' Bins 1.) Remove inner door panels, and outer door cover. Apply double row of rope caulk along door flanges, noting how door and bin sheets lap.
  • Page 66 DOOR FRAME ASSEMBLY DOOR HOLD BACK DETAIL...
  • Page 67 PART NUMBER PART NUMBER QUANTITY QUANTITY 12'-27' BIN DIA. 30'-60' BIN DIA. 12'-27' BIN 30'-60' BIN DESCRIPTION 4.00" CORR. 4.00" CORR. DIAMETER DIAMETER OUTER DOOR COVER WD-039 WD-039 OUTER COVER LATCH BRACKET WD-2854 WD-2854 OUTER COVER HINGE BRACKET WD-225 WD-225 DOOR COVER BRACE SECTION WD-035 WD-035...
  • Page 68 WD-041-2 WD-041-1 WD-1984 Field drill holes in sidewall sheet on ridge of corrugation. Center bin step under door...
  • Page 69 Once the door frame has been placed and secured, continue adding necessary sidewall ring(s). To the lower edge of the bottom ring, attach the base angle ring. Before lowering the bin, apply mastic sealer to the entire underneath side of the base angle. (See below.) Next, lower the bin onto the foundation and check for an adequate seal.
  • Page 70 The Hi-Lo Thermostat is designed for use with the GSI Top Dry Crop Dryer units. It comes with one (1) thermostat which is adjustable and cycles the heater from high to low flame. the Hi-Lo Thermostat also comes with a thermometer for monitoring the plenum temperature. Installation: Locate mounting position of thermostat as shown in Figure #58.
  • Page 71 THE GSI GROUP, INC. 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.