1. Introduction Dryer Operation Thank you for choosing a GSI Vision X-Stream Series Grain Dryer. These units are among the finest grain dryers ever built; designed to give you excellent operating performance and reliable service for many years. This manual describes the installation and operation for all standard production model dryers. These dryers are available with liquid propane or natural gas fuel supply, single phase 230 volt, three phase 230 or 460 volt (60 Hz) electrical power.
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1. Introduction Operating Precautions (Continued) 12. Be certain that capacities of auxiliary conveyors are matched to dryer auger capacities. 13. Do not operate in an area where combustible material will be drawn into the fan. 14. The operating and safety recommendations in this manual pertain to the common cereal grains as indicated.
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.
2. Safety Emergency Stop Switch The Emergency Stop switch is located on the upper control box door. Pushing the Emergency Stop switch will interrupt the control power and stop all dryer functions. Pushing the Emergency Stop switch does not interrupt the main power to the upper control box panel.
3. Safety Decals The GSI Group, Inc. recommends contacting your local power company and having a representative survey your installation, so the wiring is compatible with their system and adequate power is supplied to the unit. Safety decals should be read and understood by all people in the grain handling area.
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Keep hands clear. Do not operate without guards in place. Failure to do so could result in serious injury. GSI Group 217-226-4421 DC-972 Decal: DC-974 DANGER DANGER Decal DC-974 has several different locations. Two (2) are located on the front end panel below the fan/heater.
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Failure to do so will result in serious injury or death. DC-973 GSI Group 217-226-4421 Decal: DC-1227 WARNING Decal DC-1227 is located on the Flame and pressure beyond fan/heater access door.
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Stay clear of rotating blade. Blade could start automatically. Can cause serious injury. Disconnect power before servicing. DC-1225 DC-1225 GSI Group 217-226-4421 Decal: DC-388 3/4" MINIMUM BOLT DIAMETER Decal DC-388 is located on the Hitch pin must be hitch tongue.
1 0” depth with 36” wide x 36” deep footings along each side #4 reinforcing rods on 1’ - 0” centers. Both directions in slab and bottom of footing. Use 3/4” x 9 5/8” minimum anchors with epoxy. GSI part numbers: anchor (GTC-0003) epoxy (GTC-0004) Minimum soil bearing capacity = 2000 PSF.
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4. Specifications Concrete Specifications: • Compressive Strength @ 28 days -- 4000 PSI • Minimum Cement Content -- 6 sacks/yard. • Maximum slump -- 4" +/- 1". Figure 4B Example of Stack Dryer Footprint PNEG-1622 2 and 3 Module Vision X-Stream Dryers...
5. Vision Control Panel Heater switches Touch screen switches Load auger switch Unload auger switch Moisture manager printer (optional) Operator light switch Control power switch Stop switch Start switch Meter roll speed Figure 5A Control Power Switch The control power to energize the Vision Control System is turned ON or OFF with this switch. NOTE: This switch does not disconnect the power that is present at the breakers, contactors, transformer(s), fuses or other electrical components found in the upper and lower control boxes.
5. Vision Control Panel Load Auger Switch This is used to select the operation of the fill auger. In both the auto and manual position, the load auger will operate if the dryer is low on grain and will automatically shut off when the dryer is full. In the AUTO position only the dryer will shut down after a preset period of time set on the out of grain timer if grain flow is interrupted to the dryer.
6. Vision Touch Screen Display This section should be read first to familiarize yourself with the Vision Control Computer. The dryer operation section on Page 39 of this manual will refer to instructions in this section. Boot Screen With the Power switch in the ON position, pushing the Start switch will start the Vision Computer. The first screen to appear will be the Boot screen.
6. Vision Touch Screen Display As you can see the Operation screen is divided into five (5) sections. 1. Dryer Operation Animation: Located on the left side of the Operation screen the operation animation shows the status of the fan/heaters, load and unload augers and meter rolls. It will also display the grain temperature, moisture content, M/C set point and bushel counter.
6. Vision Touch Screen Display Optional Operation Screen An optional Operation screen can be selected that shows a graph instead of the chart view. (Touching the View button at the bottom of the display will bring up the View Selection window. Notice that you have four (4) selections to choose from).
6. Vision Touch Screen Display Touch the Graph View button then touch the Exit button. The Optional Operation screen will appear. Notice that the Dryer Status Chart and the Plenum(s) sections have been replaced by the graph view (See Figure 6E).
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6. Vision Touch Screen Display 1. Load Delay: (Default setting - 2 minutes) This delay is used to delay the starting of the load auger when the dryer is unloading to prevent the load auger from cycling to often. The load delay is active only when the Load Auger switch in the AUTO position.
6. Vision Touch Screen Display Setting the Temperatures To adjust the temperature set points, touch the Temp Button at the bottom of Operation screen. A new screen will appear called the Select Temperature Set Point to Modify screen. As you can see you modify the set point for each of the plenums by touching the desired Plenum button.
6. Vision Touch Screen Display The Setup Screen The Setup screen will allow you to setup other parameters of the dryer. To use the Setup screen touch the Setup Button. The Select Hardware Setup Parameter to Modify screen will now be displayed. As you can see there several different parameters that can be modified on this screen: 1.
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6. Vision Touch Screen Display 6. Burner Mode: Touching the Burner Mode button will display the Select Burner Mode screen. (See Figure 6I). NOTE: The bottom fan/heater on a two (2) fan dryer is always fan heater 1. The Select Burner Mode screen will allow the operator to select the type of burner operation for each burner.
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6. Vision Touch Screen Display 8. BHP Calibration: Touching the BHP Calibration button will display the Unload Bushels Setup screen. (See Figure 6K.) As you can see the bushel counter can be cleared by touching the CLEAR button. However if the bushel counter is out of calibration it can be calibrated by touching the INCREASE and DECREASE buttons.
6. Vision Touch Screen Display Viewing the Owners Manuals on the Display Screen The operators and parts manuals can be viewed on the display screen. To view a manual touch the View Button. When the View Selection window appears touch the Owners Manual button. A new display will appear called an explorer window.
6. Vision Touch Screen Display Viewing the Dryer Shut Down History The dryer will keep track of all safety shut down warnings. To view the shut down history, touch the View Button. When the View Selection window appears touch the History button. A new window called Shut down History will appear.
7. Test Firing Dryer Pre-Season Checks This section gives a series of checks to be carried out on the dryer before starting for the first time in the drying season. If any of the checks fail to produce the stated result, you should consult your dealer. You should not attempt to use the dryer unless all the pre-start checks have been successfully completed.
7. Test Firing Load Auger With the grain supply shut off, quickly bump the Load Auger switch to manual and see if the load auger rotates clockwise as viewed from the drive end or counterclockwise if the dryer is a front load model. If the wet grain supply auxiliary is wired to the dryer it should also rotate in the correct direction at this time.
7. Test Firing Burner Safety To check the burner safety function, first make sure the main gas valve is OFF. Turn the Fan switch ON and allow the fan to start. Then, turn the Heater switch ON for that fan. The dryer will shut down after 20 seconds.
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7. Test Firing Low-Fire needle valve Pressure Watch gauge Watch gauge regulator for pressure for pressure (High-Fire) Figure 7A LP Pipe Train Low-Fire needle valve Supply line ball valve (High-Fire) Watch gauge for pressure Figure 7B NG Pipe Train PNEG-1622 2 and 3 Module Vision X-Stream Dryers...
7. Test Firing Dryer Shut Down To shut down the dryer, 1. Close the fuel supply valve at the tank or valve along the fuel line. 2. If the burner is operating, let the dryer run out of fuel and it will shut down automatically due to loss of flame.
8. Dryer Operation Dryer Start-Up and Operation Full Heat Drying Full Heat Operation With this type of drying, the grain is discharged hot, with no cooling. Drying capacity is substantially higher with FULL HEAT than the DRY AND COOL process. Final Moisture From 1% to 3% apparent moisture is usually removed in the cooling process, so hot shelled corn is removed from the dryer at about 17% moisture if the final desired moisture content is 15%.
8. Dryer Operation Setting the Temperatures To adjust the temperature set points touch the Temp Button at the bottom of Operation screen. A new screen will appear called the Select Temperature Set point to Modify screen on Page 28 for instructions on how to set the temperatures.
8. Dryer Operation Continuous Flow Drying Mode Using Regulation of Grain Temperature Full Heat - Continuous Flow Operation This section begins with Step 7 and it is assumed that Step 1 through Step 6 in the start-up procedure described on Page 40 have been completed.
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8. Dryer Operation 11. Turn each FAN switch to ON. The fan will start and the switch will illuminate when air pressure is detected. 12. Start each burner by turning the HEATER switch to ON. After purging for approximately 10 seconds the burner will fire and the Heater switch will illuminate.
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8. Dryer Operation 16. Increase the drying temperature to 190°F for single fans or for multiple fan dryers set the heat chambers 30° to 60° apart. Hottest at the top, most cool at the bottom. (See setting the temperatures on Page 28.) 17.
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8. Dryer Operation Figure 8D 20. After the run time in Step 21 you are ready to adjust the moisture control and the meter roll speeds if required. Each time you make an adjustment to the moisture control it will take about the time shown in the drying charts to see the results of this adjustment.
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8. Dryer Operation 8. Make sure the UNLOAD switch is OFF. 9. Open the main fuel supply valve on the tank if using LP gas or open the fuel supply line if using natural gas. Turn ON the Maxon electric shut off valve, if so equipped or open the manual shut off valve to allow fuel flow to the dryer.
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8. Dryer Operation Figure 8F 18. DO NOT TRY TO ADJUST THE DRYER FOR MOISTURE DURING THIS PROCESS OR YOU WILL ESTABLISH HIGH AND LOW SWINGS IN THE MOISTURE CONTROL. IT WILL TAKE SEVERAL HOURS TO WORK ITSELF OUT. 19. After the run time in Step 17 you are ready to set up the moisture control.
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8. Dryer Operation 20. Now that the UNLOAD AUGER switch is in the AUTO position the moisture control is active. Now touch the M/C button at the bottom of the Dryer Operation screen. When the Modify Temperature Set Point window appears set the upper temperature to about 130°F. Let the dryer run on these settings for at least 30-40 minutes before making further adjustments to the moisture control or meter roll settings.
8. Dryer Operation Figure 8I To set the inner or outer limits touch the SELECT button until the desired limit is highlighted with a red square. The offset for that limit may now be adjusted by touching the INC (increase) or DEC (decrease) buttons.
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8. Dryer Operation Figure 8J 9. Now touch the 5 SPD SETUP button. When the Bracketed 5 Speed Moisture Control Setup is displayed touch the SELECT DEFAULTS button. Touch the ACCEPT/EXIT buttons to save these settings in the computer and return to the Dryer Operation screen. Figure 8K 10.
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8. Dryer Operation 12. The dryer should already be filled with grain. Turn the LOAD AUGER switch to the AUTO position. In both the AUTO and MANUAL positions, the Dryer Grain Level switch will automatically keep the dryer full of grain. In the AUTO position, the dryer will shut down after a preset time period using the out of grain timer.
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8. Dryer Operation 18. After the run time in Step 17 begin to test the moisture content with a Moisture Tester you consider to be accurate. Test at least three (3) samples for accuracy. Having determined the average discharge moisture, you may now calibrate the incoming and outgoing moisture sensors on the dryer. To do this you will need to press the SETUP button and return to the Hardware Parameter screen.
8. Dryer Operation Continuous Flow Drying Mode using Regulation of Moisture: Variable MR Speed Full Heat - Continuous Flow Operation This section begins with Step 7 and it is assumed that Step 1 through Step 6 in the start-up procedure described on Page 40 have been completed.
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8. Dryer Operation 14. Turn the UNLOAD switch to AUTO. The Vision control computer will now be in a 30 minute learning mode. Any adjustment to the dryer should be kept to a minimum. If the output moisture content needs to be adjusted do it now to to maximize the learning curve.
10. Illustration Supply Line (LP Shown) Fan/Heater control box Supply line (liquid) solenoid Plenum air pressure switches Left grain High Limit thermostat Supply line (liquid) solenoid Safety shutoff valve (Maxon) Figure 10A PNEG-1622 2 and 3 Module Vision X-Stream Dryers...
10. Illustration LP Vaporizer Coil Adjustment Loosen this bolt to adjust the vaporizer coil. Loosen this bolt to adjust the vaporizer coil. Figure 10C NG Fan/Heater Pipe Train Pressure Cycling solenoid Firing valve Main solenoid valve gauge valve Orifice is attached here Low-fire gas pressure adjustment screw Figure 10D...
10. Illustration Fan/Heater Control Box Fan motor Fenwal flame Vision fan/heater board Fan motor overload detection board contactor Figure 10E Top Auger Drive Check top auger drive belt tension after several hours of initial operation. Check periodically thereafter. Figure 10F PNEG-1622 2 and 3 Module Vision X-Stream Dryers...
10. Illustration Discharge Safety Switch Metering roll speed sensor Discharge safety (See Figure 10H.) shut off switch Discharge box Discharge bearing plate Figure 10G Meter Roll Speed Sensor Meter roll timing gear Meter roll speed sensor Figure 10H PNEG-1622 2 and 3 Module Vision X-Stream Dryers...
10. Illustration Upper Control Box Load, unload, Load, unload, and auxiliary motor and auxiliary overloads and Fan motor motor circuit breakers contactors circuit breakers Dryer network board Power distribution block Terminal strip Main circuit breaker SCR Contactor and SCR Circuit SCR Transformer Grounding strip circuit breakers...
10. Illustration Lower Control Box (Back Panel) 12 Volt power supply 5 Volt power supply Moisture control board Figure 10K PNEG-1622 2 and 3 Module Vision X-Stream Dryers...
11. Service Before starting any repairs or maintenance on the dryer, observe the following safety steps: 1. Isolate the whole system from the electrical supply by switching OFF the power isolator and locking it. 2. Isolate the dryer from the gas supply by shutting OFF the main gas valve (if necessary lock the valve). 3.
11. Service 11. Operate dryer clean out levers and check clean out hatch mechanism for proper operation. With hatch open, inspect and remove any accumulation of dirt, fines and foreign material from the bottom auger trough area. NOTE: Do not allow high moisture material to collect within the tough area. It may adversely affect metal parts.
11. Service Suggested Lubricant’s Insulation Class Consistency Type Grease Frame Type A and B Medium Polyurea Shell Dolium R 215T and smaller A and B Medium Polyurea Shell Dolium R 254 and larger F and H Medium Polyurea Shell Dolium R Fan Blade Removal and Installation Always disconnect and lock out power before working on or around fan.
11. Service Installing the Fan Blade Assembly 1. Clean the motor shaft, key, bushing and the bore of the hub with a non-residual cleaner, such as brake parts cleaner or electric parts cleaner. It is important that these mating surfaces be clean and dry and no grease or oil is present.
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11. Service Installing the Fan Blade Assembly (Continued) Figure 11A Vane Axial Fan Do not exceed the torque specifications listed on the bushing bolt torque chart. Exceeding the recommended torque will crack the fan hub. CAUTION Bolt Torque Bolt Torque Bushing Bolt Thread Bushing...
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11. Service Installing the Fan Blade Assembly (Continued) Figure 11B Cutaway Drawing of Typical Propeller Figure 11D Cap Screw Arrangement for Resassembly Installation Ref # Description Rotation Propeller Taper-Lock Bushing Cap Screw (Grade 5) Threaded Holes in Bushing Cap screws installed into threaded holes to force propeller off bushing.
11. Service Fan Motor Removal In the event of motor failure, remove the motor as described and take it to the nearest service station. An authorized service station is the only place that can provide possible motor warranty. Motor service and repair at other places will be at owners expense.
11. Service Heater Parts Removal and Installation Most of the heater parts can be removed by simply identifying any attached wiring and then disconnecting the obvious mounting parts. 1. Flame Sensor: Disconnect the wire connector and unscrew the flame sensor out of its mounting bracket.
11. Service Main Controls 1. SCR Speed Control: The metering roll speed pots on the front of the control box regulate the speed of the DC motor which drives the metering rolls. The scale of adjustment is from 0 to 999 which represents the flow of grain past the metering rolls as a percent of the maximum grain discharge rate for the dryer.
11. Service Shut down warning window: Touch the HELP button to display the Shut down Help Window (See Figure 11F.) Figure 11E Shut down Help Window will display a picture of the part that may have caused the shut down. Figure 11F Fan and Heater Generated Errors The following is a list of errors that are generated with the fan and heater controller.
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11. Service Fan x Loss of Airflow This error message is displayed when airflow (air pressure) has been established but was lost for some reason. This could happen if while during the dryers operation the grain has settled or shrinkage in the grain columns causing a loss of air pressure in the plenum chamber.
11. Service Motor Overload x One of the thermal overloads on either the fan, load, unload or auxiliary motors has opened, indicating an over current condition. The overloads must be manually reset. The message will distinguish between which fan overload caused the shut down. The reference to the number one is telling you that it is fan number 1 which is the bottom most fan.
11. Service Load Motor Overload The motor overload has tripped on the Load Motor Overload located in the upper control box. This can occur if this safety looses 12 VDC to terminal J1-03 on the Input/Output board. Push the red button on the overload to reset this error.
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11. Service Network Failed I/O This error is generated whenever Input/Output board (upper control panel) has lost its communications link with the Master (lower control panel door) and the Fan/Heater boards. Check the ethernet cable jacks to make sure they are plugged in tightly. There are three (3) LED lights next to this plug, one indicates power and the other two indicate data being transmitted.
11. Service Vision Diagnostics The DIAGNOSTICS button can be accessed by first touching the SETUP button at the bottom of the Main Operation Screen. When the Hardware Setup Parameter screen appears touch the DIAGNOSTICS button to display the System Diagnostics window. (See Figure 11H.) Figure 11H Display Input/Output Testing...
11. Service 2. Check Switch Wiring is used to check the switch panel switch function. A switch circuit that is on an functioning properly will have a check mark next to it. (See Figure 11J.) Figure 11J Air Switch The air switch box contains a button that will disable the plenum air switch. This is use to test fire the fan/ heaters when the dryer is empty.
1. Setup Metering Rolls adjustments are factory set and only need to adjusted when installing a new SCR board. Refer to GSI manual PNEG-1544 Vision SCR board calibration. 2. Set MR Speed Via Screen can be used if the meter roll speed adjustment knob malfunctions or if you prefer to adjust the meter roll speed by using the Touch screen.
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 workmanship.
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