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GSi 1100 Series Operator's Manual

1 and 2 fan vision series portable dryers
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1 and 2 Fan Vision Series
Portable Dryers
Operator's Manual
PNEG-1456
Date: 08-02-10
PNEG-1456

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Summary of Contents for GSi 1100 Series

  • Page 1 1 and 2 Fan Vision Series Portable Dryers Operator’s Manual PNEG-1456 Date: 08-02-10 PNEG-1456...
  • Page 2 PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...

  • Page 3: Table Of Contents

    Table of Contents Contents Chapter 1 Safety ..............................4 Safety Guidelines ..........................4 Dryer Operation ............................. 5 Emergency Stop Switch ........................5 Safety Precautions ..........................6 Chapter 2 Decals ..............................8 Chapter 3 Specifications .............................12 Dryer Dimensions ..........................12 Chapter 4 Test Firing ............................16 Dryer Pre-Season Checks ........................

  • Page 4: Chapter 1 Safety

    1. 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 5: Dryer Operation

    1. Safety Dryer Operation Thank you for choosing a GSI product. It is designed to give excellent performance and service for many years. This manual describes the operation and service for all standard production model dryers. These models are available for liquid propane or natural gas fuel supply, with either 1 phase 230 volt, or 3 phase 230 or 440 volt electrical power.

  • Page 6: Safety Precautions

    1. Safety Safety Precautions READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION SAVE FOR FUTURE REFERENCE 1. Read and understand the operating manual before attempting to operate the dryer. 2. NEVER operate the dryer while the guards are removed. 3. Power supply should be OFF for service of electrical components. Use CAUTION in checking voltage or other procedures requiring the power to be ON.
  • Page 7 1. Safety Use Caution in the Operation of this Equipment This dryer is designed and manufactured with operator safety in mind. However, the very nature of a grain dryer having a gas burner, high voltage electrical equipment and high speed rotating parts, presents hazards to personnel which cannot be completely safeguarded against without interfering with the efficient operation of the dryer and reasonable access to its components.

  • Page 8: Chapter 2 Decals

    2. Decals The GSI Group recommends contacting the local power company and having a representative survey the 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.
  • Page 9 2. Decals Decal: DC-972 WARNING! Decal DC-972 is located on the bottom auger belt guard and the front bearing plate (which is visible when the bottom auger belt guard is removed). An alternate location would be at the rear of the dryer for portable dryers equipped with the Front Discharge Option.
  • Page 10 2. Decals Decal: DC-973 Decal DC-973 is located on the rear plenum access door (inside and outside). Automatic equipment can start at anytime. Do not enter until fuel is shut off and electrical power is locked in off position. Failure to do so will result in serious injury or death.
  • Page 11 2. Decals Decal: DC-1225 WARNING Decal DC-1225 is located on the fan/heater access door. Stay clear of rotating blade. Blade could start automatically. Can cause serious injury. Disconnect power before servicing. DC-1225 Decal: DC-388 3/4" MINIMUM BOLT DIAMETER Decal DC-388 is located on the Hitch pin must be hitch tongue.

  • Page 12: Chapter 3 Specifications

    3. Specifications Dryer Dimensions Figure 3A Figure 3B PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...
  • Page 13 3. Specifications Single Module Transport and Installation Dimensions Values are Valid for Transportation of Stack Modules Dryer Installed Height Transport Installed Height w/o Frame Transport Installed Transport Basket Height Width Wet Bin Width Width Length Length Wet Bin Standard Top 1108T 13' 5'' 14' 6''...
  • Page 14 3. Specifications 1200 Series profile 1200S Series profile 1100 Series profile Figure 3C 1100 Series Dryer Specifications 1108T 1112 1114 1116 1118 1120 1122 1126 Total Holding Capacity (Bushels) Grain Column Holding Capacity (Bushels) 28'' 36'' 40'' 40'' 42'' 42''...
  • Page 15 3. Specifications 1200 Series Dryer Specifications 1214 1216 1218 1220 1222 1226 Total Holding Capacity (Bushels) Grain Column Holding Capacity (Bushels) 26'' 10-13 HP 26'' 10-13 HP 26'' 10-13 HP 28'' 10-13 HP 28'' 10-13 HP 28'' 10-13 HP 36'' 10-13 HP 36'' 15 HP 36'' 15 HP 40"...

  • Page 16: Chapter 4 Test Firing

    4. Test Firing Dryer Pre-Season Checks Before staring the drying for the first time in a drying season, perform the following checks. If any of the checks fail to produce the stated result, the customer should consult your dealer. Do not attempt to use the dryer unless all the pre-start checks have been successfully completed. Before attempting to operate the dryer, make sure all safety shields are in place, all bottoms are cleaned out and rear access doors are closed and all personnel are clear of the dryer.

  • Page 17: Load Auger

    4. Test Firing Load Auger With the grain supply shut off, quickly flip 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.

  • Page 18: Burner Safety

    4. 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. Turn the Heater switch ON for that fan. The dryer will shutdown after 20 seconds. The safety message, “Ignition Failure Fan #”...
  • Page 19 4. Test Firing Low-fire needle valve Watch gauge for pressure Pressure regulator (high-fire) Figure 4A Liquid Propane (LP) Pipe Train Low-fire needle valve Watch gauge for pressure Supply line ball valve (high-fire) Figure 4B Natural Gas (NG) Pipe Train PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...

  • Page 20: Dryer Shutdown

    4. Test Firing Dryer Shutdown To shutdown 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 shutdown automatically due to loss of flame.

  • Page 21: Chapter 5 Dryer Operation

    5. 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 with the DRY AND COOL process. Final Moisture The cooling process usually removes 1% to 3% moisture.

  • Page 22: Timer And Delay Setting

    5. Dryer Operation Timer and Delay Setting To set the timers, select the button at the bottom of the Default Operation Screen. The “Select Timers to Modify” Screen will appear. See instructions in Vision Manual to set the timer and delays. Setting the Temperatures To adjust the temperature setpoints, touch the button at the bottom of the Default Operation...

  • Page 23: Continuous Flow Drying Mode Using Regulation Of Grain Temperature

    5. 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 22 have been completed.
  • Page 24 5. Dryer Operation 13. Refer to the manual PNEG-1650 for the full heat chart settings that correspond to the model of dryer. Note the settings for Initial Moisture, Moisture Removed, Approximate Dry Time, 1 Speed, 2 Speed Low and 2 Speed High. Select the line that has the initial starting moisture. These are the settings that will be referred to during this start-up procedure.
  • Page 25 5. Dryer Operation Figure 5C 19. With the Unload Auger switch in the AUTO position, the moisture control is active. Select the M/C button at the bottom of the Default Operation Screen. When the “Modify Temperature Setpoint” window appears, set the temperature to approximately 105°F. Let the dryer run on these settings before adjusting moisture or meter roll settings.
  • Page 26 5. Dryer Operation Dry and Cool Continuous Flow Operation This section begins with Step 7 and it is assumed that Step 1 through Step 6 in the start-up procedures described on Page 22 have been completed. In this example, we will again assume that incoming grain moisture content is 25% and a 10 point moisture removal is the grain drying goal.
  • Page 27 5. Dryer Operation 14. Run the bottom fan (to be used for cooling later) and heater(s) for, approximately 20 minutes. This will start the bottom drying, so it can cool before discharging grain. 15. Run the fans and burners for approximately 10% longer than the estimated dry time for the incoming moisture.
  • Page 28 5. Dryer Operation Figure 5G 20. With the Unload Auger switch in the AUTO position, the moisture control is active. Select the M/C button at the bottom of the Default Operation Screen. When the “Modify Temperature Setpoint” window appears, set the upper temperature to approximately 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.
  • Page 29 5. Dryer Operation 5 Speed setup button 5 Speed box is checked to show that 5 speed option is selected. Figure 5H Touch the 5 SPD Setup button to display the bracketed 5 Speed Moisture Control Setup Screen. Figure 5I To set the inner or outer limits, press the Select button until the desired limit is highlighted with a red square.

  • Page 30: Continuous Flow Drying Mode Using Regulation Of Moisture: 5 Mr Sp

    5. Dryer Operation Continuous Flow Drying Mode Using Regulation of Moisture: 5 MR SP 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 22 have been completed.
  • Page 31 5. Dryer Operation Figure 5K 10. Make sure the Unload switch is OFF. 11. Open the main fuel supply valve on the tank if using LP gas, or the valve in 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.
  • Page 32 5. Dryer Operation 17. After the time in Step 16 on Page 31, turn the Unload Auger switch to MANUAL and set the Meter Roll Speed (Manual Speed). Remember that Manual is a true Manual operation with no moisture control. The meter rolls will run at the speed selected using the Meter Roll Speed Encoder. To set the Meter Roll speed, press the Meter Roll Adjustment knob.
  • Page 33 5. Dryer Operation Calibrate sensors by touching the arrow buttons. Figure 5M 19. Once the discharged grain has reached the desired moisture content, turn the Unload switch to AUTO. 20. With Unload Auger switch is in the AUTO position, the Moisture Control is active. Touch the M/C button at the bottom right of the Default Operation Screen.

  • Page 34: Chapter 6 Illustrations

    6. Illustrations Fan/Heater control box Supply line (liquid) solenoid Plenum air pressure switches Left grain high-limit thermostat Supply line (liquid) solenoid Safety shut off valve (Maxon) Figure 6A Supply Line (Liquid Propane (LP) Shown) PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...
  • Page 35 6. Illustrations Low-fire gas pressure Burner high-limit Pressure gauge Main solenoid valve adjustment screw thermostat Firing valve Cycling solenoid valve Relief valve Regulator “Y” Strainer Vapor high-limit switch Vaporizer coil Figure 6B Liquid Propane (LP) Fan/Heater Pipe Train Loosen this bolt to adjust the vaporizer coil.
  • Page 36 6. Illustrations Main solenoid valve Pressure gauge Cycling solenoid valve Firing valve Low-fire gas pressure adjustment screw Orifice is attached here. Figure 6D Natural gas (NG) Fan/Heater Pipe Train Natural gas (NG) supply line Adjust the high-fire gas pressure at this valve on natural gas (NG) models.
  • Page 37 6. Illustrations Fenwal flame Vision fan/heater board Fan motor overload Fan motor contactor detection board Figure 6F Fan/Heater Control Box Check top auger drive belt tension after several hours of initial operation. Check periodically thereafter. Figure 6G Top Auger Drive PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...
  • Page 38 6. Illustrations Discharge safety shut off switch Metering roll speed sensor (See Figure 6I.) Discharge bearing plate Discharge box Figure 6H Discharge Safety Switch Meter roll Meter roll timing gear speed sensor Figure 6I Meter Roll Speed Sensor PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...
  • Page 39 6. Illustrations Load, unload and auxiliary motor overloads and Terminal strip contactors Dryer network Input/Output board Fan motor circuit breakers Load, unload and auxiliary motor circuit breakers Power distribution block Main circuit breaker SCR contactor and SCR circuit board SCR transformer Grounding strip circuit breakers Figure 6J Upper Control Box...
  • Page 40 6. Illustrations Display Input/Output board Moisture control printer Control panel switches module (optional) Figure 6K Control Panel (Rear) PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...
  • Page 41 6. Illustrations 12 Volt power supply 5 Volt power supply Moisture control board Figure 6L Lower Control Box (Back Panel) PNEG-1456 1 and 2 Fan Vision Series Portable Dryers...

  • Page 42: Chapter 7 Service

    7. Service Before starting any repairs or maintenance on the dryer, observe the following safety steps: 1. Isolate the entire 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.

  • Page 43: Lubrication Procedure

    7. Service 12. Inspect the entire dryer for loose, worn or damaged parts. Include check of auger flighting, metering rolls and other internal parts. Check that temperature sensors within the air plenum chamber are secured within insulated clamps and do not chafe on other metal parts. 13.

  • Page 44: Fan Blade Removal And Installation

    Failure to meet this requirement could result in the blade running out of balance and potentially exploding. Balancing the blade is a specialist’s job, if in doubt contact GSI or your dealer. The fan blade is secured to the motor shaft with a taper-lock bushing, motor shaft key and three (3) cap screws.

  • Page 45: Heater Parts Removal And Installation

    7. Service 1. Make sure power is shut off and locked out. Remove fan guard and blade. 2. Remove cover from fan/heater control box and disconnect the motor lead wires from within the box. NOTE: Tag or otherwise identify wires for ease of reassembly. 3.

  • Page 46: Metering Roll Servicing

    7. Service Metering Roll Servicing This dryer is equipped with an SCR metering roll drive assembly. The metering rolls are driven by a separate DC type electric motor. This is a variable speed motor controlled by an electric SCR control inside the main control box.

  • Page 47: Chapter 8 Warranty

    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.
  • Page 48 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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