T-Series Tower Dryer Operation Manual PNEG-1458 Version: 1.
All information, illustrations, photos and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
Table of Contents Contents Chapter 1 Safety .....................................................................................................................................................5 Safety Guidelines .................................................................................................................................. 5 Dryer Operation .....................................................................................................................................
Table of Contents Chapter 8 Dryer Operation ..................................................................................................................................37 Dryer Start-Up and Operation ............................................................................................................. 37 Dryer Shut Down ................................................................................................................................. 37 Initial Setup Parameters ..................
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. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
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 for all standard production model dryers. These dryers are available with liquid propane or natural gas fuel supply and 3 phase 230, 380, 460 or 575 volts (50 Hz or 60 Hz) electrical power. Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer.
1. Safety Operating Precautions READ THESE INSTRUCTIONS BEFORE INSTALLATION AND OPERATION SAVE FOR FUTURE REFERENCE 1. Read and understand the operations manual before attempting to operate the unit. 2. Keep ALL guards, safety decals and safety devices in place. NEVER operate dryer while guards are removed. 3. Keep visitors, children and untrained personnel away from dryer at all times. 4. Never attempt to operate the dryer by jumping or otherwise bypassing any safety devices on the unit. 5.
1. Safety Prepare for Emergencies Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. Keep Emergency Equipment Quickly Accessible Wear Protective Clothing Wear close-fitting clothing and safety equipment appropriate to the job. Eye Protection Remove all jewelry. Tie long hair up and back. Gloves Wear safety glasses at all times to protect eyes from debris.
2. Safety Decals Contact the local power company to have a representative survey the installation to assure 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. Inspect all decals and replace any that are illegible, worn or missing. Contact your dealer or the factory to order replacement decals. If a decal is damaged or is missing, contact: GSI Decals 1004 E. Illinois St. Assumption, IL.
2. Safety Decals WARNING! DO NOT STAND ON DRUM! Rotating drum will cause serious injury or death. Disconnect power before servicing. DC-1062 Decal: DC-1062 Flame and pressure beyond door. May cause serious injury. Do not enter when dryer is running. Decal DC-1062 is located inside the cooling section of the dryer on the two access doors to the metering section. DC-1061 Decal: DC-1061 Decal DC-1061 is located on the outside of the heat section door. WARNING! Airborne particles during operation.
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4. Dryer Installation Dryer Layout System Layout Consider the grain handling system and location of storage bins and existing conveyors when selecting dryer site, to facilitate wet grain supply and dry grain discharge to conveyors. Other considerations are prevailing wind direction, fuel and power supply locations, noise and convenience of control location.
Concrete specifications Compressive strength @ 28 days - - 4000 PSI Minimum cement content - - 6 sacks/yard Maximum slump - - 4" ± 1" NOTES: 1. Foundation design based on net soil bearing pressure of 3000 PSF. 2. Site shall be free of any debris or vegetation and well drained. 3. All reinforcing steel to be A-615 grade 40 deformed bars. 4.
Concrete specifications Compressive strength @ 28 days - - 4000 PSI Minimum cement content - - 6 sacks/yard Maximum slump - - 4" ± 1" NOTES: 1. Foundation design based on net soil bearing pressure of 3000 PSF. 2. Site shall be free of any debris or vegetation and well drained. 3. All reinforcing steel to be A-615 grade 40 deformed bars. 4.
Concrete specifications Compressive strength @ 28 days - - 4000 PSI Minimum cement content - - 6 sacks/yard Maximum slump - - 4" ± 1" NOTES: 1. Foundation design based on net soil bearing pressure of 3000 PSF. 2. Site shall be free of any debris or vegetation and well drained. 3. All reinforcing steel to be A-615 grade 40 deformed bars. 4.
4. Dryer Installation Fuel Supply See Table on Page 20 for recommended line size. Figure 4D Liquid Propane (LP) Fuel Supply Connection to natural gas manifold on dryer See Table on Page 20 for recommended line size. Natural gas meter and regulator. See Table on Page 20 for required pressure and typical maximum fuel flow rates.
4. Dryer Installation Fuel System Recommendations 1050 1260 1575 1875 20100 24100 11100000 11100000 16654000 17669000 21298000 23393000 Maximum Fuel Usage (Gal/Hr) 121 121 182 193 233 255 Recommended Liquid Line Size (>100') 3/4" 3/4" 3/4" 1" 1" 1" 0.625" 0.625" 0.7187" 0.787" 0.781" 0.781" 9 9 9 9 9 9 11100000 11100000 16654000 17669000 21298000 23393000 11100 11100 16654 17669 21298 23393 2" 2" 2-1/2" 2-1/2" 2-1/2" 2-1/2" 0.7187" 0.7187" 0.
4. Dryer Installation Proper Installation of Ground Rod It is not recommended that the rod be driven into dry ground. Follow these instructions for proper installation. 1. Dig a hole large enough to hold one to two (2) gallons of water. 2. Fill hole with water. 3. Insert rod through water and jab it into the ground. 4. Continue jabbing the rod up and down. The water will work its way down the hole, making it possible to work the rod completely into the ground.
5. Operating Controls Vision Control Panel Layout Touch screen Heater switch Fan switch Load auger switch Unload auger switch Operator light switch Control power switch Stop switch Start switch Meter roll speed Figure 5A The vision control system is a state of the art dryer controller used on several GSI drying products. The vision control can operate any dryer in either a batch or a continuous flow mode.
5. Operating Controls Heater Switch The burner is turned ON or OFF with this switch. Turning the switch to the ON position will start the burner ignition sequence if the fan is also running. Turning the switch to the OFF position turns the burner OFF. The light inside of the switch will illuminate only when the flame sensor detects the burner flame. (NOTE: The heater AUTO position is not used.) Load Auger Switch This switch is used to select the operation of the wet fill conveyor.
6. Vision Touch Screen Display 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. (See Figure 6A.) Notice that there are four (4) “buttons” on the Boot screen. Install Dryer Software and Get Program From USB Flash buttons are only used for program updates that may be released at a later date. Touching the Start Dryer button will display the Default Operation screen.
6. Vision Touch Screen Display Figure 6B Setting the Timers Setting the timers for the dryer is a simple procedure. To set the timers, touch the button at the bottom of Operation screen. A new screen will appear called the Select Timers to Modify screen. (See Figure 6C on Page 26.) As you can see there are five (5) timers that you can modify: 1. Load delay: This delay is used to delay the starting of the load conveyor when the dryer is unloading to prevent the load conveyor from cycling to often. 2.
6. Vision Touch Screen Display Modifying timer set point Operation screen for setting timers Figure 6C To setup a timer touch the button of the timer you wish to modify. The Modify Timer Set Point screen will then be displayed. (See Figure 6C.) Note that there are two (2) number pads on this Modify screen. The left number pad is used to modify the minutes and the right number pad will modify the seconds.
6. Vision Touch Screen Display Figure 6D The plenum temperature set point range is 80°F-250°F and the current temperature set point for each plenum is displayed next to the corresponding Plenum button. The grain temperature set point range is 80°F-150°F and the current temperature set point for the grain temperature is displayed next to the Grain Temperature button. Modifying a temperature set point is much like setting a timer described on Page 25.
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 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: Figure 6E 1. Drying mode: Touching the Drying Mode button will display the Select Drying Mode window. Continuous flow will be the only option for Tower Dryers. 2.
6. Vision Touch Screen Display 4. Plenum temperature manager: Touching the plenum temperature manager will display a Configuration screen that will allow you to turn this feature ON or OFF. Also, a Configuration section is presented so that the user can edit the behavior of this option. Figure 6G 5. Burner mode: Touching the Burner Mode button will display the Select Burner Mode screen. (See Figure 6H.) Tower dryer burner mode should always be set to ALL HIGH\LOW.
6. Vision Touch Screen Display 6. Calibrate moisture sensor: Touching this button will display the Configuration screen to adjust the offset for wet and dry moisture and temperature. Figure 6I 7. Extended setup: Touching this button will display a setup menu with extended features and options.
6. Vision Touch Screen Display 1. Diagnostics: The Diagnostics operations are described in greater detail in the service section on Page 49 of this manual. 2. Differential: Touching the Differential button will display the Modify Burner Differential Settings screen. (See Figure 6K.) Adjusting the burner differential settings allows the operator to keep the plenum temperature within a certain range.
6. Vision Touch Screen Display 4. BPH Calibration: Touching the BHP Calibration button will display the Unload Bushels Setup screen. (See Figure 6M.) 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 6. Temperature scale: Touch the Temperature Scale button to choose either English units or SI units temperature scales. Depending what temperature scale you now operating in touching this button will display a pop-up window asking if you want to switch to SI (celsius, metric tons, etc.,) or English units (fahrenheit, bushels, etc.). 7. Dryer model: Touching the Dryer Model button will display the Dryer Hardware Setup window.
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 check all filling equipment for proper rotation. Turn the Load Auger switch to the AUTO position. The filling equipment should run for eight (8) minutes and then the dryer will shut down leaving the safety shut down message (out of grain warning) displayed. Press the Dryer Power Stop button to reset the panel, then press the Start button.
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. 3. Close the fuel valve at the dryer and press the Dryer Power Stop button. 4. Turn OFF the control power. 5. Turn OFF the safety disconnect handle on the front of the power box and turn OFF the main power to the dryer.
8. Dryer Operation Dryer Start-Up and Operation Drying Temperatures Shelled Corn For shelled corn with an initial moisture content of 20%-30%, the recommended drying temperature is 210°F-220°F (93°C-104°C). For lower initial moisture content, lower drying temperatures in the 180°F-200°F (82°C-93°C) range. Small Grain For drying small grain (wheat, oats, barley, milo), 150°F (66°C) is suggested. Soybeans Drying temperatures are critical in drying soybeans.
8. Dryer Operation 1. Load delay: 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. 2. Out of grain (OOG) timer: The OOG timer should be set to the maximum time it takes for the dryer to refill during continuous or batch drying modes. Note that the Vision computer will display the time required to fill the dryer on the previous load operation to aid you in setting an accurate time.
8. Dryer Operation Figure 8B Setting the Temperatures Setting the temperature set points for the dryer is a simple procedure. To adjust the temperature set points touch the button at the bottom of Operation screen. A new screen will appear called the Select Temperature Set Point to Modify screen. (See Figure 8C.) As you can see you modify the set point for the plenum by touching the Plenum 1 Temperature button.
8. Dryer Operation The grain temperature set point range is 80°F-150°F and the current temperature set point for the grain temperature is displayed next to the Grain Temperature button. Modifying a temperature set point is much like setting a timer described on Page 25. Touch the desired button of the set point you wish to change. The Modify Temperature Set Point screen will appear. Enter the desired temperature using the displayed number pad then touch the Accept button.
8. Dryer Operation Continuous Flow Drying Mode Using Advanced Moisture Control 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. 7. Touch the Setup button at the bottom of the Dryer Operation screen. Once the Hardware Parameter screen is displayed, touch the Drying Mode button. NOTE: Tower Dryers are always operated in the continuous flow mode.
8. Dryer Operation 9. Now touch the Setup button >> Extended Setup button >> Printer Setup. When the Storage Parameters window appears select the type of grain that is to be dried and select the storage bin to be used (the bin number is for reference only and has nothing to do with the control of moisture). The optional printer can also be enabled or disabled by touching the Printer Setup button. After you have made the selection, touch the Exit button to accept and exit. 10.
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10. Service Pre-Seasonal Inspection and Service The dryer is made of weather-resistant material and is designed to require minimum service. However, each season we recommend the following items be checked before the unit is used and any damaged or questionable parts replaced. These checks will help eliminate possible failures and assure dependable operation of the equipment. 1. Shut off electrical power.
10. Service 6. When drying dirty corn in high humidity conditions, sludge may build up in the upper outside sheets of the dryer. This build up can be removed by either washing the sheets down with a high pressure water hose or by shutting incoming grain, dropping the grain level to below the plugged area and then running the fans and burner to dry the affected area. Tapping or sweeping the sheets will dislodge debris.
10. Service Pre-Season Service Check List ___ Lubricate blower bearings. ___ Lubricate blower motor bearings, if needed. ___ Check blower belts and adjust if necessary. ___ Clean burner ports. ___ Inspect flame rod and spark ignitor. ___ Check oil levels in gear boxes. ___ Inspect divider hopper between heat and cooling section. Clean if necessary. ___ Inspect bindicator grain level switches. ___ Inspect metering system access door cover seals.
10. Service Lubrication Table Location Instructions Type of Lubrication Lubrication Interval Accutrol (sweep unload) top and bottom drive bearings. Lubricate slowly until lube shows through seal. Wipe clean. High quality, grade #2 lithium based grease. Beginning of season (annually). Accutrol (sweep unload) coupling hub. Remove the two (2) lube plugs from the cover. Lubricate slowly until grease begins seeping through relief plug. High quality, grade #2 lithium based grease.
11. Safety Circuit Shut Down Messages Shut down warning window: Touch the Help button to display the shut down help window. Figure 11A Fan/Heater Generated Errors The following is a list of errors that are generated with the fan/heater controller. Each fan/heater has there own set of safeties which are listed below. You will need to inspect the controller associated with the error. Example: If you get this error, it is telling you the problem is with housing 1 (bottom most fan) High-Limit.
11. Safety Circuit Shut Down Messages Grain Temp Short x This error indicates there is a shorted condition with one of the grain temperature sensors located inside the left or right grain columns. This could be a shorted sensor or the sensor wires could be shorted. Grain x Overheat An over temperature condition has occurred in one of the grain columns causing the control to shut down the dryer. This control is set at 210°F (99°C) and automatically resets itself when cool.
11. Safety Circuit Shut Down Messages Input/Output Generated Errors The following is a list of errors that are generated with the Input/Output board located in the upper control box. Air System Failure A shut down has occurred due to a air system that was installed with an integral safety switch that was in the unit. The air system safety connections are located in the upper control box on the terminal strip. This can occur if this safety looses 12 VDC to terminal J1-10 on the Input/Output board.
11. Safety Circuit Shut Down Messages Unload Motor Overload The motor overload has tripped on the unload motor overload located in the upper control box. This indicates that 12 VDC has been lost to terminal J1-02 on the Input/Output board. Push the Red button on the overload to reset this error. This is caused from the motor operating with to much of a work load, which in turn uses more current (amperage). If the problem reoccurs then check the motor to make sure it is not being overworked.
11. Safety Circuit Shut Down Messages Figure 11B Plenum Temp Open x This error indicates there is a open condition with the plenum temperature sensor located inside the plenum chamber. This could be a open sensor or the sensor wires could have a open connection. Plenum Temp Short x This error indicates there is a shorted condition with the plenum temperature sensor located inside the plenum chamber. This could be a shorted sensor or the sensor wires could be shorted.
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NOTES 80 PNEG-1458 T-Series Tower Dryer
13. Warranty GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
This equipment shall be installed in accordance with the current installation codes and applicable regulations, which should be carefully followed in all cases. 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.
