2001 Top Dry Service School GSI / Top Dry 2001 Service School Manual 1
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2001 Top Dry Service School Table of Contents Safety Pages .....................................................................................5 Duct Installation ...............................................................................7 Access Door Installation ................................................................13 Product Updates ............................................................................21 Software Changes .............................................................
2001 Top Dry Service School SAFETY Roof Damage Warning and Disclaimer GSI DOES NOT WARRANT ANY ROOF DAMAGE CAUSED BY EXCESSIVE VACUUM OR INTERNAL PRESSURE FROM FANS OR OTHER AIR MOVING SYSTEMS. ADEQUATE VENTILATION AND/OR "MAKEUP AIR" DEVICES SHOULD BE PROVIDED FOR ALL POWERED AIR HANDLING SYSTEMS. GSI DOES NOT RECOMMEND THE USE OF DOWNWARD FLOW SYSTEMS (SUCTION). SEVERE ROOF DAMAGE CAN RESULT FROM ANY BLOCKAGE OF AIR PASSAGES.
2001 Top Dry Service School SAFETY Grain Systems, 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 your unit. Safety decals should be read and understood by all people in the grain handling area. The rotating blade, fire warning decals and voltage danger decal must be displayed on the fan can.
SAFETY PRECAUTIONS 2001 Top Dry Service School READ THESE INSTRUCTIONS BEFORE OPERATION AND SERVICE SAVE FOR FUTURE REFERENCE 1. Read and understand the operating manual before trying to operate the dryer. 2. 3. 4. 5. 6. Use Caution in the Operation of this Equipment The design and manufacture of this Power supply should be OFF for service of electrical components. Use dryer is directed toward operator CAUTION in checking voltage or other procedures requiring power to safety.
2001 Top Dry Service School Duct Installation GSI / Top Dry Duct Installation 7
Duct Installation 2001 Top Dry Service School Top Elbow Duct Section 8
2001 Top Dry Service School Duct Installation 44 Duct Section 9
Duct Installation 2001 Top Dry Service School 32 Duct Section 10
2001 Top Dry Service School Duct Installation Bottom Elbow Duct Section 11
Duct Installation 2001 Top Dry Service School Duct Assembly - (Six Ring Top Dry) 12
2001 Top Dry Service School Access Door Installation GSI / Top Dry Access Door Installation 13
Access Door Installation 2001 Top Dry Service School Access Door Assembly - Expanded View 14
2001 Top Dry Service School Access Door Installation Front Z-Bracket Assembly Rear Z-Bracket Assembly 15
Access Door Installation 2001 Top Dry Service School Front Top/Bottom Z-Bracket Assembly - Side View Front Side Z-Bracket Assembly - Top View 16
2001 Top Dry Service School Access Door Installation Front Door Latch Assembly Rear Door Latch Assembly 17
Access Door Installation 2001 Top Dry Service School Front Doors to Z-Bracket Assembly Rear Doors to Z-Bracket Assembly 18
2001 Top Dry Service School Access Door Installation Rear Door Latch Catch Assembly 19
Access Door Installation 2001 Top Dry Service School Access Door to Entrance Sheet Assembly 20
2001 Top Dry Service School Product Updates GSI / Top Dry Product Updates * * * * * * * * Corrugated Stiffener Bracket Eave Clips Partially Perforated Eave Flashing Venturi Airswitch Brake Motor IEC Electrical Components Grain Temperature Sensor Junction Box Rotary Switch Junction Box 21
Product Updates 2001 Top Dry Service School Old-Style Stiffener Bracket w/Corrugation Spacers 22
2001 Top Dry Service School Product Updates TD-100977 Corrugated Stiffener Bracket Corrugated Stiffener Bracket Installation 23
Product Updates 2001 Top Dry Service School TD - 101017 Large Eave Clip (30 & 36 Diameter Top Dry Units) TD-101074 Small Eave Clip (21 & 24 Diameter Top Dry UNits) New Top Dry Eave Clip Design 24
Product Updates 2001 Top Dry Service School TAF-6112 Discharge Flow Plate (Not Used) 12.
Product Updates 2001 Top Dry Service School TF-1807 Top Dry Venturi Airswitch Assembly New Venturi Airswitch Assembly 26
2001 Top Dry Service School Product Updates Airswitch and Venturi Location 27
Product Updates 2001 Top Dry Service School Venturi Airswitch Adjustment 28
2001 Top Dry Service School Product Updates Venturi Location - End View 29
Product Updates 2001 Top Dry Service School C-7815 Brake Motor: Data 30
2001 Top Dry Service School Product Updates C-7815 Brake Motor: Dimensions 31
Product Updates 2001 Top Dry Service School C-7815 Brake Motor: Connections 32
2001 Top Dry Service School Product Updates IEC Component Usage & Specifications Voltage: Horsepower: Contactor: Overload: Max. Amps 220v1ph 15 D03-0496 D03-0484 65 Voltage: Horsepower: Contactor: Overload: Max. Amps 208v3ph 30 D03-0498 D03-0486 97 Voltage: Horsepower: Contactor: Overload: Max. Amps 208v3ph 40 D03-0539 D03-0540 140 Voltage: Horsepower: Contactor: Overload: Max. Amps 208v3ph 15 D03-0495 D03-0482 43 Voltage: Horsepower: Contactor: Overload: Max.
Product Updates 2001 Top Dry Service School TAF-6166 Grain Temperature Sensor Junction Box 34
2001 Top Dry Service School Product Updates TAF-6167 Drying Chamber Rotary Switch Junction Box 35
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2001 Top Dry Service School Software Changes GSI / Top Dry Software Changes * Series 2000 Batch Software Changes * Series 2000 Autoflow Software Changes * Current Software Versions 37
Software Changes 2001 Top Dry Service School Series 2000 Batch Software Changes Significant Software changes since July 12, 1995 (Software version number is displayed at all units on power-up) ¨ Software Version 0.30 ¨ Flame out is 10 seconds. The ignitor shuts off in 7.5 seconds. ¨ Software Version 0.25 Added a mode select for the humidity and ambient temperature sensor. Uses the mode switch inputs (fan bypass). Software Version 0.29 Eliminated the diesel option.
2001 Top Dry Service School Software Changes Series 2000 Batch Software Changes Significant Software changes since July 12, 1995,continued (Software version number is displayed at all units on power-up) ¨ Software Version 0.22 ¨ Created a option in the set-up mode: L or no L When setting the dry time to 3.2 hours the display would say .32 hours when the program mode was exited - fixed that problem.
Software Changes 2001 Top Dry Service School Series 2000 Batch Software Changes Significant Software changes since July 12, 1995, ¨ (Software version number is displayed at all units on power-up) ¨ Software Version 0.12 Software Version 0.17 When a shutdown occurs while drying you can view the number of hours since the shutdown by pressing the decrease switch. On two fan units, when the slave shut down the master fan would not shut off-fixed that problem.
2001 Top Dry Service School Software Changes Series 2000 Autoflow Heater Software Changes Significant Software Changes (Software version number is displayed on power-up) VERSION: 1.) 1.09 Provided On-Off burner option. VERSION: 1.) 1.08 Fixed software to correctly display Celsius temperatures. 2.) VERSION: 1.) 2.) Increased the hysteresis of the air switch to avoid unnecessary shutdowns. 1.07 Changed the way the check sum works.
Software Changes 2001 Top Dry Service School Series 2000 Autoflow Display Software Changes Significant Software Changes (Software version number is displayed on power-up) VERSION: 2.11 1) Burner differential would not stay at 1 deg. F when the dryer was turn off, using 2.10, now it does. 2) When grain reaches the Storage Chamber Rotary Switch, the dryer will enter a Cool Down Mode. The fan will run and cool the grain for 10 minutes before shutting down due to a Storage Chamber Full error.
2001 Top Dry Service School Software Changes Series 2000 Autoflow Display Software Changes Significant Software Changes (Software version number is displayed on power-up) VERSION: 1) 2.10 Changed the Minimum Burner Differential to 1 Deg. Fahrenheit 2) Fixed the problem where the burner was not shutting off when the Dry & Hold switch was placed in the On position, the Dry Cycle was complete, and the Dryer was in the Cool Cycle.
Software Changes 2001 Top Dry Service School Series 2000 Autoflow Display Software Changes Significant Software Canges (Software version number is displayed at all units on power-up) VERSION: 1) 2.09 Selection screen for On-Off burner. This cannot be used in conjunction with diesel burner. NOTE: Must change heater software also. Use following version number or higher: Heater ==> 1.09 VERSION: 1) 2.08 Changed the burner differential setup screen to correctly display Celsius temperatures.
2001 Top Dry Service School Software Changes Series 2000 Autoflow Display Software Changes Significant Software Canges (Software version number is displayed at all units on power-up) VERSION: 2.03 NOTE: This software originated from 1.06 and is intended to fix version 2.00. 1) Added diesel option which if selected pulses the ignitor relay on for about 1/2second after power to burner is on. 2) Took out option for modem string until it is needed. 3) Added safeties for thermistor shorts and opens.
Software Changes 2001 Top Dry Service School Series 2000 Autoflow Display Software Changes Significant Software Canges (Software version number is displayed at all units on power-up) VERSION: 1) 2.02 Changed the Batch percentage off selection screen to a screen which allows you to enter a time (just like any other timer) at which the dryer will shut off loading in the DRY TIME. The timer is called the BATCH FILL TIME. VERSION: 1) 2.
2001 Top Dry Service School Software Changes Series 2000 Autoflow Display Software Changes Significant Software Canges (Software version number is displayed at all units on power-up) VERSION: 1) 2.00 Fixed hour timer so dryer will now show running time of dryer.
2001 Top Dry Service School Software Changes Series 2000 Autoflow Display Software Changes Significant Software Changes (Software version number is displayed at all units on power-up) VERSION: 1) 2) 1.06 Fixed dryer so the grain hi limit occurs at 20 F above the grain temp setpoint. Made timeout on the open/close of the actuator 20 seconds instead of 15 seconds. This extra time was added to compensate for the weaker batteries taking longer to close the chutes. VERSION: 1) 1.
2001 Top Dry Service School Current Top Dry Software Software Changes Top Dry Series 2000 Autoflow Display Computer Board - Version 2.11 Heater Computer Board - Version 1.09 Input/ Output Board - Version 1.07 Top Dry Series 2000 Batch Heater Software Series 2000 Batch - Version .30 EMCS Top Dry Autoflow Software EMCS Autoflow - Version 2.
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2001 Top Dry Service School Additional Information GSI / Top Dry Additional Information * Top Dry Sidewall Gauges * Top Dry Stiffener Gauges * Fan Blade Data 51
2001 Top Dry Service School Additional Information 120,1$/ ',$ 180%(5 2) 5,1*6 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 6LGHZDOO 2) 6,'(:$// )W 2) 6,'(:$// %DVH 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD
2001 Top Dry Service School Additional Information 120,1$/ ',$ 180%(5 2) 5,1*6 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 6WLIIHQHU 2) 6,'(:$// )W 2) 6,'(:$// %DVH 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ 5LQJ JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD JD
Additional Information 'LDPHWHU +S 530 2001 Top Dry Service School *6, 0XOWL :LQJ R ' =5 33* %63 ' =5 33* %63 R ' =5 33* %63 7) =5 33* R ' ' =5 33* %63 =5 33* %63 R ' ' =5 33* %63 =5 33*
Software Diagnostics 2001 Top Dry Service School GSI / Top Dry Software Diagnostics * Series 2000 Batch Fan & Heater * Series 2000 Autoflow Display * Series 2000 Autoflow Fan & Heater 55
Software Diagnostics 2001 Top Dry Service School Series 2000 Batch Fan / Heater Initializing the Novram Turn the Control Power off . Hold down the Program Temperature switch. Turn the Control Power switch on with the Program Temperature switch held down. 56 Press the Increase switch until 7 is on the display. Press the Program Temperature switch again. You have two seconds to depress the Increase or Decrease switches at the same time. The NOVRAM has been initialized.
2001 Top Dry Service School Software Diagnostics Series 2000 Batch Fan / Heater Programming Set-up Variables Turn the Control Power off F or C will be displayed. Turn the Control Power switch on with the Program Temperature switch held down. Press the Increase switch until 3 is on the display. Use the Increase or Decrease switch to toggle between F or C. F - Temperatures displayed in Fahrenheit. C-Temperatures displayed in Celsius. Press the Program Temperature switch again.
Software Diagnostics 2001 Top Dry Service School Series 2000 Batch Fan / Heater CAUTION: DO NOT ATTEMPT BELOW PROCEDURE WITH GAS LINE CONNECTED. Diagnostic Mode 58 Press the Program Dry time switch to engage the Fan starter-Fan will be displayed. Turn the Control Power off . Hold down the Program Temperature switch. Press the Increase switch to make the ignitor spark-IN will be displayed. Turn the Control Power switch on with the Program Temperature switch held down.
2001 Top Dry Service School Software Diagnostics Series 2000 Autoflow Display Keypad Test Control Switch Tests Turn the Control Power off. Turn the Control Power off . Turn the Control Power switch on with the Help Switch pressed. Turn the Control Power switch on with the Plenum and Grain Switches pressed. The Keypad Switches can now be tested. The Control Switches can now be tested.
Software Diagnostics 2001 Top Dry Service School Series 2000 Autoflow Fan / Heater CAUTION: DO NOT ATTEMPT BELOW PROCEDURE WITH GAS LINE CONNECTED. Diagnostic Mode 60 Turn the Control Power off . Hold down the Program Temperature switch. Turn the Control Power switch on with the Program Temperature switch held down. Press the Program Dry time switch to engage the Fan Starter. Press the Program Temperature switch to start theIgnitor.
2001 Top Dry Service School WARRANTY THE GSI GROUP, INC. ("GSI") WARRANTS ALL PRODUCTS MANUFACTURED BY GSI TO BE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USAGE AND CONDITIONS FOR A PERIOD OF TWELVE MONTHS AFTER RETAIL SALE TO THE ORIGINAL END USER OF SUCH PRODUCTS. GSI'S ONLY OBLIGATION IS, AND PURCHASER'S SOLE REMEDY SHALL BE FOR GSI, TO REPAIR OR REPLACE, AT GSI'S OPTION AND EXPENSE, PRODUCTS THAT, IN GSI'S SOLE JUDGMENT, CONTAIN A MATERIAL DEFECT DUE TO MATERIALS OR WORKMANSHIP.
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