CE Approved GSI/FFI Portable Dryer Manual Operation Manual PNEG-1717 Date: 12-08-10 PNEG-1717
Models: 1100 Series (Models 1108, 1112, 1114, 1116, 1118, 1120, 1122, 1126, CFAB190, CFAB270, CFAB320, CFAB370, CFAB400, CFAB460, CFAB510, CFAB511, CFAB601) 1200 Series (Models 1214, 1216, 1218, 1220, 1222, 1226, C2120A, C2122A, C2125A, C2130A, C2132A, C2140A) 1200S Series (Models 1214S, 1218S, 1220S, 1222S, 1226S, CF2141, CF2181, CF500H, CF2221, CF650M) 2300 Series (Models 2314, 2318, 2320, 2322, 2326, CF3142, CF3182, CF3202, CF3222, CF3262) 2400 Series (Models 2420, 2426, CF1000H, CF1300M) 3400 Series (Mo
Table of Contents Contents Chapter 1 Introduction ..........................................................................................................................................5 Dryer Operation ..................................................................................................................................... 5 Precautions ...........................................................................................................................................
Table of Contents Chapter 9 Vision Illustrations .............................................................................................................................44 Supply Line (LP Shown) ...................................................................................................................... 44 28" and 36" LP 1" NPT CE Pipe Train Assembly ................................................................................ 45 40" and 42" LP 1-1/2" NPT CE Pipe Train Assembly ............
1. Introduction Dryer Operation Thank you for choosing a CE Approved GSI/FFI Vision Series Grain Dryers. Please read this manual before installing or operating the equipment. Make sure you and your employees understand all requirements, hazards and precautions associated with this equipment. Failure to do so could result in SERIOUS INJURY or DEATH. Ensure you have the correct power and fuel supply for the dryer. Do not alter or modify this equipment.
2. Safety Safety Guidelines Please observe all safety decals on the equipment.
2. Safety Emergency Stop Switch In event of emergency press the Emergency Stop to stop all dryer equipment (power remains connected).
3. Installation Transporting/Single Fan When transporting the unit by truck or tractor observe these precautions: 1. Hitch height is 350 mm-430 mm. (See Figure 3A.) Figure 3A 2. Hitch pin diameter is 19 mm minimum. Must be securely fastened. (See Figure 3B.) 3. Minimize hitch movement. (See Figure 3B.) Washers Locking nut 19 mm Minimum diameter Figure 3B 4. Use a safety chain. (See Figure 3A.) 5. Dryer must be empty and towed in accordance with all applicable laws and regulations. 6.
3. Installation Location of the Dryer Consider: 1. Wet and dry storage. 2. Access to power and fuel. 3. Proximity to other structures (maintain minimum 1m clearance). 4. Noise. 5. Over head power. Always install out of doors. Foundation 1. Dryers should be installed on a suitable concrete base/foundation. 2. Foundation design to be carried out by qualified engineer. 3. Take into account ground and weather conditions. 4. Refer to dryer dimensions and loaded weights in table on Pages 11-25.
3. Installation Dry Grain Removal 1. Dry grain discharges at the rear of the dryer (front discharge optional). 2. Dry grain removal may be electrically connected to contactor provided in the main control box. Electrical Power Supply Ensure there is adequate electrical power to run the dryer. All supplies are 3 phase with neutral and include a protective earth. NOTE: Excessive voltage drops can cause equipment malfunction.
3. Installation Fuel Liquid Propane (LP) Liquid Draw 1. LPG is vaporized internally within the dryer. 2. LPG pipework and controls from the tank to the dryer must be installed by the gas supplier in accordance with local directives, laws, codes and regulations. 3. LPG tank should be sized to supply the full heat input of all burners. See heater rating plates for details.
3. Installation Natural Gas (N) Gas Volume and Pressure Natural gas supply should offer: 1. 49 MJ/m3 calorific value. 2. 650 mBar supply pressure. (Lower pressure may inhibit dryer performance.) 3. Gas pipework and controls from the supply to the dryer must be installed by the gas supplier in accordance with local directives, laws, codes and regulations. Check the supply capacity against dryer requirements. (See heater rating plates for details.
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4. Specifications Single Module FFI Transport and Installation Dimensions Values are Valid for Transportation of Stack Modules A Dryer Basket B C D E Height w/o Wet Bin Frame Width F G H Installed Height Transport Installed Height Width Wet Bin Standard Top Transport Installed Transport Width Length Length 190T (10') 3632.2 (11' 11") 2438.4 (8') 3962.4 (13') 3505.2 (11' 6") 3124.2 (10' 3") 1955.8 (6' 5") 2438.4 (8') 5232.4 (17' 2") 5842.0 (19' 2") 270 (12') 4089.4 (13' 5") 2438.
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4. Specifications 2 Fan CFAB Specifications CFAB 510 22' CFAB 600 26' Total Holding Capacity (Bushels) 622 735 Grain Column Holding Capacity (Bushels) 506 598 Fans 36" 15 HP (2) 40" 20 HP (2) Top Auger 8" Dia. 7.5 HP 8" Dia. 10 HP 2800 2800 Bottom Auger 8" Dia. 5 HP 8" Dia. 7.
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4. Specifications Single Module GSI Transport and Installation Dimensions Values are Valid for Transportation of Stack Modules A B Transport Height Installed Width 1108T 4089.4 (13' 5'') 1112 Dryer Basket C D E F G H Height w/o Wet Bin Frame Width Transport Width Installed Length Transport Length Installed Height Wet Bin Standard Top 2438.4 (8') 4419.6 (14' 6'') 3962.4 (13') 3581.4 (11' 9'') 1955.8 (6' 5'') 2438.4 (8') 4622.8 (15' 2'') 5232.4 (17' 2'') 4089.4 (13' 5'') 2438.
4. Specifications GSI Specifications 1100 Series profile 1200 Series profile 1200S Series profile Figure 4F 1100 Series Dryer Specifications 1108T 1112 1114 1116 1118 1120 1122 1126 Total Holding Capacity (Bushels) 190 327 381 436 490 544 599 708 Grain Column Holding Capacity (Bushels) 160 282 329 376 423 470 517 611 Fans 28'' 10-13 HP 36'' 15 HP 40'' 15 HP 40'' 15 HP 42'' 20 HP 42'' 25 HP 42'' 30 HP 42'' 40 HP Top Auger 8'' Dia. 1-1/2 HP 8'' Dia. 3 HP 8'' Dia.
4. Specifications 1200 Series Dryer Specifications 1214 1216 1218 1220 1222 1226 Total Holding Capacity (Bushels) 381 436 490 544 599 708 Grain Column Holding Capacity (Bushels) 329 376 423 470 517 611 Fans 26'' 10-13 HP 26'' 10-13 HP 26'' 10-13 HP 36'' 10-13 HP 36'' 15 HP 36'' 15 HP Top Auger Capacity (BPH) Bottom Auger Meter Roll Drive Capacity - Maximum Rate1 (BPH) 28'' 10-13 HP 28'' 10-13 HP 28'' 10-13 HP 40" 15 HP 42'' 20 HP 42'' 25 HP 8'' Dia. 5 HP 8'' Dia. 5 HP 8'' Dia.
4. Specifications NOTE: All dimensions are in mm.
4. Specifications All Stack Dimensions (Continued) “X” - Varies with dryer length (See Chart on Page 23.) Figure 4H Side View - 2 Module Stack Dryer “X” - Varies with dryer length (See Chart on Page 23.) Figure 4I Stack Dryer Dimension (Side View - 3 Module Stack Dryer) NOTE: All dimensions are in mm.
4. Specifications All Stack Dimensions (Continued) Dryer Installed Length (1, 2 and 3 Module Stacks) Basket Length Installed Length 14 7264.4 (23' 10") 18 8483.6 (27' 10") 20 9093.2 (29' 10") 22 9702.8 (31' 10") 26 10922.0 (35' 10") End View - 2 Module Stack Dryer End View - 3 Module Stack Dryer Figure 4J NOTE: All dimensions are in mm.
4. Specifications All Stack Specifications Total Holding Capacity (Bushels) Grain Column Holding Capacity (Bushels) 14' 18' 20' 22' 26' 731 940 1044 1149 1304 679 873 970 1067 1261 Fans 28" 10-13 HP 40" 15 HP 36" 10-12 HP 42" 20 HP 36" 15 HP 42" 25 HP 36" 15 HP 42" 30 HP 40" 25 HP 42" 40 HP Top Auger 8" Dia. 5 HP 8" Dia. 5 HP 8" Dia. 7.5 HP 8" Dia. 7.5 HP 8" Dia. 10 HP 3800 3800 3800 3800 3800 Capacity (BPH) Bottom Auger 8" Dia. 5 HP 8" Dia. 5 HP 8" Dia. 7.5 HP 8" Dia.
4. Specifications All Stack Specifications (Continued) 14' 18' 20' 22' 26' Total Holding Capacity (Bushels) 1074 1381 1534 1688 1995 Grain Column Holding Capacity (Bushels) 1022 1314 1460 1606 1898 Fans 28" 10-13 HP 40" 15 HP 36" 10-13 HP 42" 20 HP 36" 15 HP 42" 25 HP 36" 15 HP 42" 30 HP 40" 25 HP 42" 40 HP Top Auger 8" Dia. 5 HP 8" Dia. 5 HP 8" Dia. 7.5 HP 8" Dia. 7.5 HP 8" Dia. 10 HP 3800 3800 3800 3800 3800 Bottom Auger 8" Dia. 5 HP 8" Dia. 5 HP 8" Dia. 7.
4. Specifications All Stack Specifications (Continued) 3962.4 (13'-0")-OPTIONAL CATWALK J 2362.2 (7'-9")-SAFETY 812.8 (2'-8")-REAR SAFETY CAGE PLATFORM SEE NOTE 3 G H L L SEE NOTE 2 E B D C N SEE NOTE 1 A M F 4267.2 (14'-0") Figure 4K A B C D E1 F G H J L M N 14' 7048.5 660.4 4267.2 1422.4 406.4 3403.6 1466.85 (23'-1-1/2") (2'-2") (14'-0") (4'-8") (16" Min.) (11'-2") (4'-9-3/4") 203.2 (0'-8") 2438.4 7251.7 3048.0 1930.4 (8'-0") (23'-9-1/2") (10'-0") (6'-4") 18' 8267.7 660.
4. Specifications All Stack Specifications (Continued) 3962.4 (13'-0")-OPTIONAL CATWALK J 2362.2 (7'-9")-SAFETY PLATFORM 812.8 (2'-8")-REAR SAFETY CAGE SEE NOTE 3 G H K L L SEE NOTE 2 E B C D A SEE NOTE 1 N F 4267.2 (14'-0") Figure 4L A B C D 14' 7048.5 (23'-1-1/2") 660.4 (2'-2") 4267.2 1422.4 406.4 3403.6 1466.85 203.2 2438.4 914.4 7251.7 (14'-0") (4'-8") (16" Min.) (11'-2") (4'-9-3/4") (0'-8") (8'-0") (3'-0") (23'-9-1/2") 1930.4 (6'-4") 18' 8267.7 (27'-1-1/2") 660.
4. Specifications Stack Dryer Foundation Specifications Stack Dryer Foundation Basket Length Concrete Pad Size (12' x “X”)1 Concrete (Cubic Yards) (Cubic Meters) #4 Rebar (Feet)2 (mm) Anchors3 14 18 20 22 26 12' (3657.6) x 24' (7315.2) 12' (3657.6) x 28' (8534.4) 12' (3657.6) x 30' (9144.0) 12' (3657.6) x 32' (9753.6) 12' (3657.6) x 36' (10972.8) 20-3/4 (15.86451) 24-1/4 (18.54046) 26 (19.87843) 27-1/2 (21.02526) 31 (23.
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5. Vision Control Panel Heater Switch 1. Selects/deselects each heater. 2. ON (1) = Burner operates with fan. 3. AUTO (0/1) = Burner operates in staged batch dry cycle only. Load Auger Switch 1. Controls the fill system and auxiliary equipment where used. 2. In all modes the load auger operates when grain level is low. 3. AUTO (0/1) = Dryer shuts down after a preset period (out of grain timer) when incoming grain flow ceases to the dryer. Timer disabled in MANUAL. Unload Switch 1.
6. Vision Touch Screen Display Boot Screen 1. With the Power switch ON, pushing the START initiates the Vision computer. 2. The boot screen has four (4) “buttons”. (See Figure 6A.) 3. The Start Dryer button enters the Default Operation screen. Buttons used to update software. (See PNEG-1506 Vision programming manual.) Figure 6A NOTE: See PNEG-1456 for vision touch screen display details.
7. Vision Test Firing Dryer Pre-Season Checks 1. Perform these checks at the start of each season. 2. If any checks fail, consult your dealer. 3. Do not use the dryer unless checks are successful. Ensure all safety shields are fitted, all doors are closed, and all personnel are clear of the dryer before starting dryer. 1. Inspect metering roll compartments for foreign objects which may cause damage. 2. Ensure that all switches on the dryer control panel are OFF. 3.
7. Vision Test Firing Dryer Pre-Season Checks (Continued) 16. Confirm that the meter roll control increases and decreases speed. NOTE: Brushes inside the DC meter roll motor to become corroded after a period of no use, causing a roll malfunction. This may be fixed by tapping the motor with a rubber mallet. Subsequent operation should be normal. 17. Check fan rotation (counterclockwise) and reverse if required. (Swap any 2 phases on the fan power supply.) 18. Check the burner safety function.
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7. Vision Test Firing Dryer Shut Down To shut down the dryer, 1. Close the fuel supply valve. 2. Let the dryer run out of fuel. 3. Press the Dryer Stop button. 4. Turn OFF the control power. 5. Turn OFF the dryer safety disconnect and turn OFF the main power to the dryer. Emergency In case of emergency, push the Emergency Stop button.
8. Vision/Dri-Tek Dryer Operation Full Heat Drying Full heat drying discharges hot grain. This yields higher drying capacity, but requires cooling elsewhere. Final Moisture Cooling will remove up to 3% additional moisture. The target moisture should be increased to allow for this to prevent over drying.
8. Vision/Dri-Tek Dryer Operation Continuous Flow Drying Mode Using Regulation of Grain Temperature Full Heat Continuous Flow Operation In this example incoming grain 25% and target is 15% moisture. 1. Set continuous flow drying. SETUP > DRYING MODE > CONTINUOUS FLOW > ACCEPT/EXIT. 2. Set drying mode. M/C SETUP > REGULATION OF GRAIN TEMPERATURE > ACCEPT/EXIT > EXIT. Figure 8A 3. Ensure the Unload switch is OFF (0). 4. Ensure fuel supply is on at all shut off valves. 5. Fill the dryer with grain.
8. Vision/Dri-Tek Dryer Operation Figure 8B 14. Set the plenums 15°C to 30°C apart. Warmest at the top. 15. DO NOT ADJUST THE DRYER FOR MOISTURE DURING THIS PROCESS. THIS WILL CAUSE CONTROL INSTABILITY. 16. After the run time in Step 13 on Page 37, set the moisture control. Unload switch = AUTO. 17. Push the meter roll adjustment knob. Ensure 2 Speed is selected. 18. Set the high and low speeds according to the drying chart. Toggle between speed settings by pressing the adjustment knob. Press ACCEPT.
8. Vision/Dri-Tek Dryer Operation Figure 8D 21. After the required run time check the outgoing moisture and adjust the moisture control/meter roll settings if required. A change in the settings will take the same drying time to show in the outgoing moisture readings. 3°C Increase in temperature = 1% Moisture reduction. Dry and Cool Continuous Flow Operation 1. Follow Steps 1-9 on Page 37 for full heat continuous flow setup. Figure 8E 2.
8. Vision/Dri-Tek Dryer Operation Continuous Flow 5 Speed Temperature Control 1. Enable the 5 Speed option: SETUP > M/C Setup > ENABLE 5 SPD TEMPERATURE. (See Figure 8F.) 2. Enter 5 Speed setup: 5 SPD SETUP. (See Figure 8G.) 3. Initially use default settings. 5 Speed setup button 5 Speed box is checked. Figure 8F Figure 8G 4. Inner and outer limits dictate the points at which the speed increases either side of the set point.
8. Vision/Dri-Tek Dryer Operation Continuous Flow Drying Mode Using Regulation of Moisture: 5 MR SP Full Heat Continuous Flow Operation 1. Follow Steps 1-8 on Page 37 for full heat continuous flow setup. 2. Set continuous flow: SETUP > DRYING MODE > CONTINUOUS FLOW > ACCEPT > EXIT. 3. Enter 5 Speed moisture regulation mode: SETUP > M/C Setup > ENABLE 5 SPD. Figure 8H 4. Set required moisture set point M/C > Enter set point > ACCEPT. 5. Setup 5 Speed control parameters: 5 SPD SETUP.
8. Vision/Dri-Tek Dryer Operation Figure 8I Figure 8J 9. Calibrate the moisture sensors, taking the average of at least three (3) samples both incoming (moist) and outgoing (dry). Step 17 on Page 38, SETUP > M/C Setup > CALIBRATE SENSORS > enter offset > ACCEPT. (See Figure 8K on Page 43.) Example: Reading = 18.3%, Sample = 17%, Offset = -1.3%. The moisture tester gives an average moisture of 17%, but the moisture sensor on the dryer reads 18.3%.
8. Vision/Dri-Tek Dryer Operation Calibrate sensors by touching the arrow buttons. Figure 8K 10. Once the discharged grain has reached the desired moisture content, turn the Unload switch to AUTO. 11. Moisture control (5 Speed) is now active. 12. If you press the meter roll knob, you will now notice that there is one meter roll speed to adjust.
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9. Vision Illustrations LP Vaporizer Coil Adjustment Loosen this bolt to adjust the vaporizer coil. Loosen this bolt to adjust the vaporizer coil.
9. Vision Illustrations See Figure 9F on Page 48 for installation to fan housing view.
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9. Vision Illustrations Vision Fan/Heater Control Box Pactrol flame detection board Fan motor contactor COFI spark igniter Vision fan/heater control board Fan motor overload Figure 9G Top Auger Drive Check top auger drive belt tension after several hours of initial operation. Check periodically thereafter.
9. Vision Illustrations Discharge Safety Switch Metering roll speed sensor (See Figure 9J.
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10. Service Safety First Before working on the dryer: 1. Switch OFF and lock the power isolator. 2. Switch OFF and lock the fuel supply. 3. Keep the keys in the possession. 4. Augers and drives may be under tension. Keep hands clear and release tension with tools. 5. Reconnect the power and fuel ONLY when all guards are correctly refitted. Seasonal Inspection/Service 1. Inspect all upper, lower and fan/heater controls for damage, foreign materials and loose connections.
10. Service Figure 10A 14. Inspect entire dryer for loose, worn or damaged parts. 15. Check of auger flighting, metering rolls and other internal parts. 16. Check that temperature sensors within air plenum chamber are secured properly. 17. Check guards are installed and damage free. 18. Check all decals are fitted and legible. 19. Test fire the dryer several weeks ahead of the drying season. Check for possible gas leaks. (See Page 32.
10. Service Lubrication Procedure 1. Always clean the grease nipple before greasing. Motor Frame # Strokes < NEMA 215 1-2 NEMA 254 - NEMA 365 2-3 > NEMA 404 3-4 2. On motors with drain plugs, remove plug and operate for 20 minute before replacing drain plug. 3. On motors equipped with slotted head grease screw, remove screw insert 5 cm to 8 cm grease on NEMA 254 motors and smaller. Insert 8 cm to 13 cm length on larger motors.
10. Service Fan Blade Removal and Installation Gently wedge the fan blade to reduce the risk of free wheeling and injury. Damaged blades must be replaced and re-balanced by a specialist. The following points must be read carefully and fully understood. Improper installation can cause a loose blade, and result in serious injury or death. Lock out power. NOTE: Bushing and blade must be re-assembled in the same alignment to preserve fan balance.
10. Service Heater Parts Removal and Installation 1. Flame sensor: Disconnect the wire connector, and unscrew the flame sensor. 2. Regulator and gas solenoid valve(s): Removal and refit of gas components must be carried out by a qualified gas fitter. The gas regulator and solenoid valve(s) are directional and must be connected as indicated. NOTE: Do not over tighten component connections. 3. Main gas orifice: a. Disconnect plumbing support brackets. b.
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12. 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.
