L Series Dryer Operation Manual Operation Manual PNEG-1459 Date: 8-01-2008 PNEG-1459
PNEG-1459 L Series Operators
CONTENTS INTRODUCTION..................................................................................................................................................4 OPERATING PRECAUTIONS................................................................................................................................................4 SAFETY.........................................................................................................................................................................
INTRODUCTION OPERATING PRECAUTIONS READ THESE INSTRUCTIONS BEFORE INSTALLATION and OPERATION. SAVE FOR FUTURE REFERENCE. Thank you for choosing a GSI Vision 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.
SAFETY SAFETY ALERT SYMBOL The symbol shown is used to call your attention to instructions concerning your personal safety. Watch for this symbol; it points out important safety precautions. It means "ATTENTION", "WARNING", "CAUTION", and "DANGER". Read the message and be cautious to the possibility of personal injury or death. WARNING! BE ALERT! Personnel operating or working around electric fans should read this manual. This manual must be delivered with the equipment to its owner.
SAFETY Decal: DC-972 Decal DC-972 is located on the bottom Decal: DC-1227 auger belt guard and the front bearing plate (which is visible when then 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 Decal DC-1227 is located on the fan/heater access door. Option. Decal: DC-1229 Decal: DC-974 Decal DC-974 has several different locations. Two are located on the front end panel below the fan/heater.
SPECIFICATIONS Models 3020L, 4026L, 6034L, 7534L, and 1038L for Dry & Cool: Designed for drying in the top 2/3 of the grain column and vacuum cooling in the lower 1/3 of the grain column, thus reclaiming the heat in the grain to preheat the drying air. AUTOMATIC CONTROL: Automatic control of loading, drying, cooling, and discharge functions. Full safety control system; automatic shutdown on wet grain outage, grain Hi-Limit, and discharge safety shutoff.
SPECIFICATIONS SPECIFICATIONS CHART TABLE 1-1 Basic Construction Grain Column by Length Grain Column Width Total Holding Capacity Wet Bin Capacity Dry Section Cool Section Transport Dimensions: Body Module Length w/ Hitch Width Height Fan Module Length Width Height Installed Dimensions Grain Section Length Fan-Heater Section Length Total Length Width - w/ Heat Reclaiming Max. Width - w/o Heat Reclaiming Overall Height Centrifugal Fan Type Fan Motor Burner - Max.
VISION CONTROL PANEL Vision Control Panel Layout Heater Switches Touch Screen Fan Switches Load Auger Switch Unload Auger Switch Moisture Manager Printer (Optional) Operator Light Switch Control Power Switch Stop Switch Start Switch Meter Roll Speed CONTROL POWER SWITCH The control power to energize the Vision Control System is turned on or off with this switch.
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. The load delay is disabled when the load auger switch is in the manual position.
VISION TOUCH SCREEN DISPLAY THIS SECTION SHOULD BE READ FIRST TO FAMILIARIZE YOURSELF WITH THE VISION CONTROL COMPUTER. THE DRYER OPERATION SECTION 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 (see image above). Notice that there are three “buttons” on the boot screen.
VISION TOUCH SCREEN DISPLAY SELECT DATA LOG SAMPLE TIME Notice the Modify button in the upper left hand side of the Dryer Status Chart. By touching this button the sample time can be changed from 1 minute to 5, 10 or 15 minutes. Select the desired sample time and touch Accept/Exit button to exit. Also notice that the chart can be cleared by selecting the Clear Table button at the bottom.
VISION TOUCH SCREEN DISPLAY 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 (shown on the left). As you can see there are 4 timers that you can modify: 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.
VISION TOUCH SCREEN DISPLAY The plenum temperature setpoint range is 80oF - 250oF, and the current temperature setpoint for each plenum is displayed next to the corresponding plenum button. The grain temperature setpoint range is 80oF - 150oF, and the current temperature setpoint for the grain temperature is displayed next to the Grain Temp. button. Modifying a temperature setpoint is much like setting a timer described on the previous page. Touch the desired button of the setpoint you wish to change.
VISION TOUCH SCREEN DISPLAY 5.) Temp Scale: Touch the Temp. 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 popup window asking if you want to switch to SI (Celsius, metric tons, etc..) or English units (Fahrenheit, bushels, etc..) 6.) Diagnostics: The Diagnostics operations are described in greater detail in the service section of this manual. 7.
VISION TOUCH SCREEN DISPLAY 10.) Meter Roll Reverse: Touch the Meter Roll Reverse button to reverse the metering rolls. Reversing the metering rolls aids in cleaning out the fine material that builds up over the course of the drying season. Just touching this button will toggle between normal meter roll operation and reversed meter roll operation. 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 button.
TEST FIRING DRYER PRESEASON 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.
TEST FIRING utes, and then the dryer will shutdown leaving the safety shutdown message (out of grain warning) displayed. Press the dryer power stop button to reset the panel, then press the start button. UNLOAD AUTO OPERATION To check auto operation place the unload switch in the auto setting. Turn the meter roll dial until the meter rolls start rotating. The bottom auger should rotate counterclockwise as viewed from the drive end.
TEST FIRING Approximate settings should be: LP Gas Natural Gas Hi-Fire 6-15 PSI (41-102 kPa) Lo-Fire 2-6 PSI (14-41 kPa) Hi-Fire 6-10 PSI (41-69 kPa) Lo-Fire 1-3 PSI (7-20 kPa) If the burner remains on hi-fire and does not cycle, increase the regulator setting on the propane models, or the supply valve on the natural gas models in order to reach the plenum set point. If the burner remains in lo-fire and does not cycle, slightly decease gas pressure with the lo-fire adjustment screw on the cycle solenoid.
DRYER OPERATION - START-UP 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%.
DRYER OPERATION - START-UP 3. Turn on the electrical power supply to the dryer, and move the safety disconnect handle mounted on the dryer’s upper power box to on. 4. Turn the control power switch to on. The switch will light up. The control computer will boot up. At this point the controller will lock out all other dryer functions. Once the boot screen appears, touch the Start Dryer button and the dryer will perform its safety circuit checks.
DRYER OPERATION - BASIC MOISTURE CONTROL CONTINUOUS FLOW DRYING MODE USING BASIC MOISTURE CONTROL Full Heat-Continuous Flow Operation This section begins with step 7 and it is assumed that steps 1 through 6 in the start-up procedure described on page 20 & 21 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.
DRYER OPERATION - BASIC MOISTURE CONTROL 18. Increase the drying temperature to 190 deg. F for single fans or for multiple fan dryers set the heat chambers 30 to 60 degrees apart. Hottest at the top, most cool at the bottom (see Setting Temperatures on page 14). 19. 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. 20.
DRYER OPERATION - BASIC MOISTURE CONTROL Dry and Cool-Continuous Flow Operation This section begins with step 7 and it is assumed that steps 1 through 6 in the start-up procedure described on page 22 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. When the Select Drying Mode window appears touch the CONTINUOUS FLOW button to select continuous flow drying mode.
DRYER OPERATION - BASIC MOISTURE CONTROL 19. 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. 20. After the run time in step 18 you are ready to set up the moisture control. Turn the UNLOAD switch to AUTO. Push the Meter Roll Adjustment knob. When the Modify Meter Roll Setpoints window appears check that Two Speed is selected (see image below).
DRYER OPERATION - INTERMEDIATE MOISTURE CONTROL CONTINUOUS FLOW DRYING MODE USING INTERMEDIATE MOISTURE CONTROL Full Heat-Continuous Flow Operation This section begins with step 7 and it is assumed that steps 1 through 6 in the start-up procedure described on page 22 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.
DRYER OPERATION - INTERMEDIATE MOISTURE CONTROL 9. You should now be back in the Moisture Control Selection window. Touch the BIN # / GRAIN TYPE button. 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). Then touch the EXIT button and return to the Moisture Control Selection window. 10.
DRYER OPERATION - INTERMEDIATE MOISTURE CONTROL 19. Run the fan(s) and heater(s) for about 10% longer than the (APPROX. DRYING TIME) required for the moisture you are trying to dry. 20. Example: 10% removal would be about 54 minutes, 15% removal would be about 76 minutes and 20% removal would be about 100 minutes. Add 10 minutes to insure that the grain is dry. 21. After the time in step 19 turn the UNLOAD AUGER switch to MANUAL. and set the METER ROLL SPEED, (MANUAL SPEED).
DRYER OPERATION - INTERMEDIATE MOISTURE CONTROL 23. Once the moisture reading at the discharge is where you want it to be, turn the UNLOAD switch to AUTO. 24. Now that the UNLOAD AUGER switch is in the AUTO position the INTERMEDIATE MOISTURE CONTROL is active. Now touch the M/C button at the bottom right of the Dryer Operation screen. When the Moisture Setpoint window appears set the moisture setpoint to the output moisture you desire.
DRYER OPERATION - ADVANCED MOISTURE CONTROL CONTINUOUS FLOW DRYING MODE USING ADVANCED MOISTURE CONTROL Full Heat-Continuous Flow Operation This section begins with step 7 and it is assumed that steps 1 through 6 in the start-up procedure described on page 22 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.
DRYER OPERATION - ADVANCED MOISTURE CONTROL number is for reference only and has nothing to do with the control of moisture). Then touch the EXIT button and return to the Moisture Control Selection window. 10. The printer can also be enabled or disabled by touching the PRINTER SETUP button. After you have made your selection, touch the EXIT button to accept and exit. 11. You will also see a button to calibrate the moisture sensors. Do not calibrate the sensors at this time.
DRYER OPERATION - ADVANCED MOISTURE CONTROL you select using the Meter Roll Speed Encoder. To do this push on the Meter Roll Adjustment knob. When the Modify Meter Roll Setpoints window appears turn the Meter Roll Adjustment knob until the speed indicator is set to the speed suggested for 1 SPEED. Grain should begin to run at this time. Run time for this is about 10% longer than the (APPROX. DRYING TIME) required for the moisture you are trying to dry.
DRYER OPERATION - ADVANCED MOISTURE CONTROL switch to advanced and take full control of the dryer. There is a count down screen in the upper right hand of the main display that shows the time remaining before the advanced moisture control begins. Dry and Cool-Continuous Flow Operation This section begins with step 7 and it is assumed that steps 1 through 6 in the start-up procedure described on page 22 have been completed. 7. Touch the SETUP button at the bottom of the Dryer Operation screen.
DRYER OPERATION - ADVANCED MOISTURE CONTROL dry. This allows the moisture in the dryer to reach an even gradient top to bottom without having any highs or lows in it. It will however, over dry some of the grain a little. 21. After the run time in step 20 begin to test the moisture content with a Moisture Tester you consider to be accurate. Test at least 3 samples for accuracy. Having determined the average discharge moisture, you may now calibrate the incoming and outgoing moisture sensors on the dryer.
DRYER OPERATION - ADVANCED MOISTURE CONTROL ADJUSTING DRYER AIRFLOW CENTRIFUGAL DRY/VACUUM COOL DRYERS The fresh air louvers, located on the sides of the fan-heater module, can be adjusted to balance the amount of cooling air required. Opening the louvers wider will reduce the amount of vacuum cooling and increase the drying airflow rate. Closing the louvers will increase the cooling airflow rate while reducing the amount of air to the drying zone.
DRYING TIME TABLES Continuous Flow Full Heat Initial Moisture 36 Moisture Removed Approx. Dry Time 1 Speed 2 Speed Low 2 Speed High 17% 2 pts. 16 min. 625 317 875 18% 3 pts. 21 min. 476 270 775 19% 4 pts. 26 min. 385 241 675 20% 5 pts. 31.5 min. 317 213 575 21% 6 pts. 37 min. 270 196 476 22% 7 pts. 41.5 min. 241 185 385 23% 8 pts. 47 min. 213 172 317 24% 9 pts. 51 min. 196 161 270 25% 10 pts. 54 min. 185 150 241 26% 11 pts. 58 min.
DRYING TIME TABLES Continuous Flow Dry & Cool Initial Moisture Moisture Removed Approx. Dry Time 1 Speed 2 Speed Low 2 Speed High 17% 2 pts. 18 min. 363 187 650 18% 3 pts. 24 min. 272 163 550 19% 4 pts. 30 min. 218 145 450 20% 5 pts. 35 min. 187 131 363 21% 6 pts. 40 min. 163 119 272 22% 7 pts. 45 min. 145 109 218 23% 8 pts. 50 min. 131 101 187 24% 9 pts. 55 min. 119 93 163 25% 10 pts. 60 min. 109 87 145 26% 11 pts. 65 min.
ILLUSTRATIONS Illustration 1 LP vaporizer assembly (C2130B, C2140B). Illustration 2 LP vaporizer assembly (C2160B, C2175B).
ILLUSTRATIONS Illustration 3 LP vaporizer assembly (C21100B). Adjust high fire pressure here for Nat. Gas models. LP models adjust high fire pressure at pressure regulator on the vaporizer assembly. Watch gauge for high fire pressure. Illustration 4 Adjust low fire pressure here for Nat. Gas and LP models. Watch guage for low fire pressure. Fuel Manifold.
ILLUSTRATIONS Illustration 5 Upper Control Box.
ILLUSTRATIONS Illustration 6 Control Panel (Rear).
ILLUSTRATIONS Illustration 7 Discharge safety switch. Metering roll speed sensor (see detailed photo below) Discharge safety shut-off switch Discharge bearing plate Discharge box Illustration 8 Meter roll speed sensor.
ILLUSTRATIONS Illustration 9 Top auger drive. Top Auger Drive Belt Retension after several hours of initial operation. Check periodically thereafter.
SERVICE Before starting any repairs or maintenance on your 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. Keep the keys in your possession. 4. Augers and drives to augers may be under some degree of tension. Avoid touching these parts with your hands until you are sure that they are free. 5.
SERVICE LUBRICATION PROCEDURE If the motors are equipped with an Alemite fitting, clean the tip of the fitting and grease with a grease gun. Use 1 or 2 full strokes on motors in NEMA 215 frame and smaller. Use 2 to 3 strokes on NEMA 254 through NEMA 365 frame. Use 3 to 4 strokes on NEMA 404 frames and larger. On motors having drain plugs, remove drain plug and operate motor for 20 minutes before replacing drain plug.
SERVICE PROPANE VAPORIZER SEASONAL INSPECTION LQUID PROPANE MODELS ONLY - Liquid propane fueled dryers are equipped with a vaporizer that operates at relatively high pressure. Since leakage can result in release of liquid propane, it is extremely important to maintain the condition of all components to provide safe operation. Vaporizers should be inspected and serviced prior to each season of operation, including the following: 1.
SAFETY CIRCUIT SHUTDOWN MESSAGES Shutdown warning window: Touch the HELP button to display the Shutdown Help Window (shown below). Shutdown Help Window will display a picture a picture of the part, that may have caused the shutdown FAN AND HEATER GENERATED ERRORS The following is a list of errors that are generated with the fan and heater controller. Each fan and heater has there own set of safeties which are listed below. You will need to inspect the controller associated with the error.
SAFETY CIRCUIT SHUTDOWN MESSAGES Flame Loss x The flame sensor has failed to detect a burner flame which had been established but was lost for some reason and there is a problem with the flame sensing circuitry or the dryer is not getting burner fuel. The message will distinguish between which burner caused the shutdown. The reference to the number one (1) is telling you that it is burner number 1 which is the bottom most fan.
SAFETY CIRCUIT SHUTDOWN MESSAGES Aux Load Overload The motor overload relay has tripped on the Aux Load Motor circuit located in the upper control box. This can occur if this safety looses 12VDC to terminal J1-05 on the I/O 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.
SAFETY CIRCUIT SHUTDOWN MESSAGES Network Failed FH x This error is generated whenever Fan/Heater board has lost its communications link with the Input/Output board (upper control panel) and the Master Display board (lower control panel). Check the ethernet cable jacks to make sure they are plugged in tightly.
PNEG-1459 L Series Operators 51
PNEG-1459 L Series Operators
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 installation occurs. The GSI Group, Inc. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 217-226-4421 Fax: 217-226-4420 e-mail: gsisales@grainsystems.com internet: http://www.grainsystems.
